Aspen Exchanger Design & Rating Programs

The Aspen Exchanger Design & Rating (EDR) software includes a number of
programs for the thermal design, mechanical design, cost estimation, and
drawings for heat exchangers and pressure vessels.
The EDR software is a combination of HTFS and B-JAC Technology.
See the What’s New section to read about the new features in this release.

The major design programs are:

Aspen Shell & Tube
Thermal Design of Shell & Tube Heat Exchangers
Exchanger

Aspen Shell & Tube Mechanical Design, C ost Estimation, and Design Drawings of
Mechanical Shell and Tube Heat Exchangers and Pressure Vessels

Aspen Air Cooled

Thermal Design of Air C ooled Heat Exchangers
Exchanger

Aspen Plate Fin Exchanger Thermal Design of Plate-fin Heat Exchangers

Aspen Fired Heater Thermal Design of Fired Heaters

Aspen Plate Exchanger Thermal Design of Plate Heat Exchangers

For the research behind the Thermal programs:

HTFS Research On-line access to the HTFS Design Reports, HTFS Research Reports,
Network HTFS Handbook, and HTFS HEATFLO database

In addition to the major design programs, these programs support the

design programs:
Metals Metal Properties Databank

Ensea Tubesheet Layout Program

Ochex Budget C ost Estimation Program

C hemical Physical Properties Databank

Props

With the V7.0 release in 2008, the program names have been updated.
Copyright
Version 2006.5
Version 2006
 What’s New in V7.3.2
Aspen EDR
The following new features and enhancements were added in release V7.3.2:
· Product Training: A new page has been added to the Online Training
Center to provide easy access to EDR product information, training materials,
and animated tutorials. You can access the new training page by selecting
Help | Product Training in EDR.
Aspen Shell & Tube Exchanger
The following new features and enhancements were added in release V7.3.2:
· A more comprehensive set of tubes is selected for vibration checks
· User can specify additional tubes on the input tube layout for vibration
checks
· Vibration-check tubes can be highlighted on the tube layout output –
including an indication of any vibration risks, from fluid elastic instabilities or
resonances
· Improved handling of U-bends and local shellside velocities in vibration
checks
· Improved tabular output from vibration and resonance checks
· Plugged tubes can be individually identified in the tube layout input, and
will appear in the tube layout output
· Properties recalculation at the beginning of a run is now an option,
rather than automatic.
· Application Control options, mainly for future use when matching
facilities are put in Simulators, to speed up solution times
· Exchanger effectiveness (fraction of maximum possible heat load) as an
input and output
· Option to specify minimum pressure in calculations. The default for this
is no longer tied to maximum pressure drop, so messages that pressure
changes have been scaled (based on maximum pressure change /minimum
pressure) will now be much less likely to occur.
· Multiple repeated near-identical messages are now suppressed, unless a
new option to show all messages is invoked
· Improved default nozzle locations for vertical E-shells
· No-U-bend-heat-transfer option now available in unbaffled exchangers
· Improved bundle entrance calculations with use-existing-layout and with
no-tubes-in-window
· Improved calculation of kettle large shell diameters
· Sealing strip orientation under user control, and always defaulting to
transverse
· Additional information in Recap of Designs table
Aspen Shell & Tube Mechanical
The following new features and enhancements were added in release V7.3.2:
· The 2011a addenda of the ASME 2010 Code and material properties
update
· Highlights in the 2011a addenda of the ASME 2010 code are:
– Revised shell longitudinal stress calculation for distributor belts
– Revised tubesheet effective bolt loads
– Revised appendix 26, expansion joints
– Updated acceptable editions of referenced standards, e.g. B16.5
· Updated wind and seismic load calculations per ASCE/SEI 7-10
· Finned tubes calculations per ASME VIII-1-UG-8(4)
· Maximum nozzle external loads per TEMA RGP-RGB-10.7
· Nozzle external loads per WRC-537
· Metric bolt dimensions per PD 5500 and EN 13445
· Added bolt tensioner clearances in flange design/rating
· Improved the application of UCS-68(c) PWHT for the reduction in impact
testing exemption temperature
· Hydrostatic pressure based on MAWP (new and cold) or MAWP (hot and
corroded)
· Improved processing of combined loadings
· New input for desired MDMT
Aspen Air Cooled Exchanger
The following new features and enhancements were added in release V7.3.2:
· Improved method for handling the viscosity of two liquid phases
· Specification of a scaling factor for heat transfer coefficients is now
available as an option for outside enhancement
· Improved reporting of humidity ratio, when wet air is cooled below its
dew point
· Corrected output for nozzle velocities with multiple bundles per unit
Aspen Fired Heater
The following new features and enhancements were added in release V7.3.2:
· Calculation and reporting of flue gas properties using Aspen Properties
· Detailed reporting the draft calculation and flue gas properties
· Improved treatment of the air pre-heater
· Detailed reporting of peak tube calculation parameters
· Improvements to the Firebox diagrams (inclusion of roof tubes)
· Increased allowance for pressure losses in U-bends and fittings
Aspen Plate Exchanger
The following new features and enhancements were added in release V7.3.2:
· Fully Implemented Active Input Checking
Aspen Plate Fin Exchanger
The following new features and enhancements were added in release V7.3.2:
· Option to specify flow maldistribution on a layer by layer basis for each
stream.
· More robust iteration for recirculating flows in thermosiphons and
kettles: heat balance is preserved when the flow changes.
· Mass flux output for X-flow streams
· Use correct mass flux in calculations for multi-pass layer elements in X-
flow exchangers (single passes in X-flow, and multi-pass elements in axial
flow are unaffected)
· Improved exchanger weight calculation in Design
· Properties recalculation at the beginning of a run is now an option,
rather than automatic
· Application Control options, mainly for future use when matching
facilities are put in Simulators, to speed up solution times
· Specification of heat load as a fraction of stream maximum load.
Exchanger effectiveness (fraction of maximum possible heat load) as an input
and output
· Option to specify minimum pressure in calculations. The default for this
is no longer tied to maximum pressure drop, so messages that pressure
changes have been scaled (based on maximum pressure change /minimum
pressure) will now be much less likely to occur.
· Multiple repeated near-identical messages are now suppressed, unless a
new option to show all messages is invoked.
· Streams with only hardway fin are now permitted.
· The layer schematic on the Layer types input is now generated even if no
exchanger length is input.
 Aspen HYSYS Integration
The Aspen Shell & Tube Exchanger (Shell&Tube), Aspen AirCooled Exchanger,
and Aspen MUSE programs are completely integrated with the Aspen HYSYS
process simulation software. Users with licenses for both the appropriate
Aspen Exchanger Design & Rating (EDR) thermal analysis software and the
Aspen HYSYS simulation software can use the Aspen EDR thermal models for
shell and tube heat exchangers, air-cooled heat exchangers, and compact
plate-fin heat exchangers within the Aspen HYSYS flowsheet.
Stream and property curve data for these models can be transferred to the
Aspen EDR programs by Aspen HYSYS. Exchanger geometry data can be
specified either through the Aspen EDR input file or from within the HYSYS
environment.
During simulation the Aspen HYSYS simulator repetitively calls the Aspen EDR
analysis programs to predict the inlet or outlet conditions of the heat transfer
equipment. The results of the analysis are returned to HYSYS which then
feeds them to the simulation solver. Detailed results of the EDR calculation
can be viewed from within the Aspen HYSYS environment or by launching the
appropriate EDR standalone program.
For HYSYS cases that use TASC and ACOL refer to the HYSYS EDR Conversion
Utility.
 Aspen Plus Integration
The Aspen Shell & Tube Exchanger (Shell&Tube), Aspen Air Cooled Exchanger
(AirCooled), and Aspen Plate Exchanger (Plate) programs are completely
integrated with the Aspen Plus process simulation software. Users with
licenses for both the Aspen Exchanger Design & Rating (EDR) thermal
analysis software and the Aspen Plus simulation software can use the Aspen
EDR thermal models for shell and tube heat exchangers, air-cooled heat
exchangers, plate and frame exchangers within the Aspen Plus flowsheet.
The models can be accessed from Aspen Plus through the HEATX unit
operation block by selecting Shell&Tube, AirCooled, or Plate rigorous heat
transfer models. Stream and property curve data for these models can be
supplied to the Aspen EDR programs by Aspen Plus or from within the Aspen
EDR input file, which is referenced in the Aspen Plus input for the block. All
exchanger geometry data must be specified through the Aspen EDR input file.
During simulation the Aspen Plus simulator repetitively calls the Aspen EDR
analysis programs to predict the outlet conditions of the heat transfer
equipment. The results of the analysis are returned to Aspen Plus which then
feeds them to subsequent blocks. A subset of the exchanger performance can
be viewed from within the Aspen Plus environment. Detailed results of the
block can be viewed from within the Aspen Plus environment by accessing the
EDR Browser or by launching the appropriate EDR standalone program.
For Aspen Plus cases that use Hetran and Aerotran, refer to the Aspen Plus
EDR Conversion Utility.
 Aspen Basic Engineering Integration
Aspen Shell & Tube Exchanger (Shell&Tube) is completely integrated with
Aspen Basic Engineering. Aspen Basic Engineering is an engineering database
tool used to capture process knowledge about the design, construction, or
operation of a process plant. The database contains a number of data models
to store information about the process streams, the process configuration, and
the individual pieces of process equipment. The user can retrieve the
information and generate specialized reports and equipment specification
sheets from the data in the database.
 License & Service Agreements
The use of the Aspen EXCHANGER DESIGN & RATING (EDR) software is
governed by a "License Agreement" for licensed clients. These are legally
binding contracts which have been signed and executed by your company and
Aspen Technology, Inc.. Some of the points included in these contracts are
shown below.
Access
Access to the programs is limited to the employees of the Customer in support
of the Customer's business. Specifically excluded is access by persons other
than the Customer's employees or use by the Customer's employees for any
purpose outside the Customer's business.
License
The license authorizes the Customer to use the licensed program on the
designated computers. Backup copies can be made.
The license is limited to the Customer, and may not be transferred or
assigned, nor may it be extended to any subsidiaries or joint ventures except
as agreed in writing between the Customer and Aspen Technology, Inc.
The licensed programs are the sole and exclusive property of Aspen
Technology, Inc. The licensed Customer does not become the owner of the
programs, but has the right to use the programs in accordance with the
license agreement.
Warranty and Limitation of Liability
The licensed programs are offered as is, and it is the Customer's responsibility
to determine if the programs are adequate for the Customer's requirements.
The Customer understands that the programs are of such complexity that
they may have inherent defects and that Aspen Technology, Inc. makes no
warranty that all such defects will be corrected. Aspen Technology, Inc. will
make a reasonable effort to correct or bypass properly reported and
documented programming errors in regularly scheduled program updates.
In no event shall Aspen Technology, Inc., its agents, suppliers, or contractors
be liable to the Customer or any third party for consequential damages arising
from use of the Aspen EDR programs. It is the Customer's responsibility to
check the results of all computer programs.
 Technical Support
AspenTech customers with a valid license and software maintenance
agreement can register to access the online AspenTech Support Center at:
http://support.aspentech.com!JumpHtml(`http://support.aspentech.com')
This Web support site allows you to:
· Access current product documentation
· Search for tech tips, solutions, and frequently asked questions (FAQs)
· Search for and download service packs and product updates
· Submit and track technical issues
· Send suggestions
· Report product defects
· Review lists of known deficiencies and defects
Registered users can also subscribe to our Technical Support e-Bulletins.
These are used to alert users to important technical support information such
as:
· Technical advisories
· Product updates and releases
Customer support is also available by phone, fax, and email. The most up-to-
date contact information is available at the AspenTech Support Center at
http://support.aspentech.com
 Version Control Utility (BJACVC.exe)
Aspen EDR provides a version control utility, BJACVC, which enables you to
switch between versions of Aspen HTFS+ and Aspen EDR. BJACVC.exe is
located in the XEQ folder of the installed EDR program.
To run the BJACVC.exe utility, locate the file using Explorer, and then double
click the file.
Selecting an ASPEN EDR program version: Select which version you wish
to run and the utility will update the MS Windows registry to allow you to run
the selected Aspen EDR or Aspen HTFS+ program version. BJACVC
automatically executes when you open an HTFS+ program version that is not
registered properly.
Copying customized files: Select the source version where your existing
customized database files are located. Next, select the target new version
where you wish to copy the database files. Next, select the files you wish to
transfer. Then select Copy to copy the customized files to the new version.
Copying program settings: To copy the program settings from an existing
HTFS+ version to a new version, select the source version. Next, select the
target new program version. Then select Apply to copy the program settings
to the new targeted version.
 User Customized Database Files
There are a number of database files that you can change to customize the
operation of the Aspen EDR, as well as alter the program answers. These
customized database files are located in a default program folder or in a user
specified directory. If you elect to use the default folder location, those
database files must be copied from the previous Aspen EDR program default
folder to the new Dat\PDA folder.
You can use the Version Control Utility, BJACVC, to copy your customized files
from an existing version to the new Aspen Exchanger Design & Rating
version.
Alternately, you can specify your own directory location for these customized
files and the Aspen EDR program will access the database from your specified
folder location. To specify your user customized database folder location,
select Tools | Program Settings | Files and provide the folder location for the
database files.
Note: If the update is installed into the directory for the previous version, the
install program will not copy over the previous version’s database files.
The following table contains a list of the database files that can be
customized.
Database Contents

Private properties chemical databank

D_FXPRIV.PDA
properties

D_IDPRIV.PDA Private properties chemical databank index

Private properties chemical databank

D_VAPRIV.PDA
properties

G_COMPNA.PDA Company name and address for drawings

G_PROFIL.PDA Default headings, input, operation options

Default materials for generic materials

N_MTLDEF.PDA
(ASME)

N_MTLDIN.PDA Default materials for generic materials (DIN)

Default materials for generic materials

N_MTLCDP.PDA
(AFNOR)

N_PARTNO.PDA Part number assignment for bill of materials

N_PRIVI.PDA Private properties materials databank index

Private properties materials databank

N_PRIVP.PDA
properties

Fabrication standards, procedures, costs,

N_STDLAB.PDA etc.

Fabrication standards as function of

N_STDMTL.PDA
materials

N_STDOPR.PDA Fabrication operation efficiencies

N_STDWLD.PDA Fabrication welding standards

N_STDPRC.PDA Private materials prices

 Accessing Aspen EDR Program Files
Most users will want their input and output files stored in a directory separate
from the Aspen EDR programs. The input and output files are read from or
written to the current directory on your PC. This allows you to organize your
input and output files however you wish. We recommend that you run from a
directory other than the directory in which the Aspen EDR programs are
installed.
 Filenames & Filetypes
Although the Aspen EDR software works on several different computers and
operating systems, there is a high degree of similarity in the use of filenames
and filetypes for input and output files.
The filename and filetype form the name under which the file is stored on the
storage medium (usually disk).
Filenames
The filename can be up to 255 characters in length and may use the letters
A-Z a-z, numbers 0-9, and special characters - _ & $.
Filetypes
The filetype (filename extension) is automatically established by the Aspen
EDR software as follows:
Filetype Description

EDR Aspen EDR Input/Output File (Release 2006 and later)

BJT Aspen EDR Input/Output File (Release 10.0 to 2006)

BFD Aspen EDR Drawing File

Aspen EDR Template file (user can save an existing *.BJT input file
BDT as a *.BDT template file, and then reuse the template to create
other design input files, using the Windows Save As feature).

BJI Aspen EDR Input File (previous versions)

BJO Aspen EDR Output File (previous versions)

BJA Aspen EDR Archive File (Input/Output data previous versions)

Whenever an Aspen EDR program requests a filename, it is expecting the

name without the filetype. The program will append the filetype.
Alternate Filetypes
Filetype Description

Aspen Hyprotech Tasc+ Output file (for import into the Aspen
TAF
Shell&TubeMech program)

HTRI Output file (for import into the Aspen Shell&TubeMech

DBO
program)

HTRI Output file (for import into the Aspen Shell&TubeMech

OUT
program)
 Importing/Exporting Design Data
AutomationX
The Aspen EDR input/results file may be exported to other OLE compliant
systems for use with other programs via various automation utilities. An
example automation file has been provided in the example sub-directory,
XMP, of the installed EDR program.
Export Drawings
Drawings may be exported to a *.DXF CAD format file or to an Autocad
inventor file.
Results
Shell&Tube, Shell&TubeMech, and AirCooled results may be exported to a
*.doc file format. Aspen Shell&TubeMech detailed results may also be
exported to an *.rtf format file.
 General Operating Procedures
Most of the Aspen EDR programs follow these general operating procedures.
1 Start Aspen EDR.
On your desktop click the Aspen Exchanger Design & Rating shortcut icon or
click Start | Programs | AspenTech | Exchanger Design & Rating V7.3 |
Exchanger Design & Rating User Interface.

2 Select required EDR program.

On the Aspen EDR Design System dialog box, do one of the following:
· On the New tab, click the checkbox next to the EDR program you want to
use and click OK.
or
· Click the Existing tab and select the file you want to open and click OK.

3 Enter the required data.

Use the Navigation Tree or click the Next button on the toolbar to display the
required input forms and sheets, and enter the data.

4 Run the problem.

On the toolbar, click the Run button, or on the menu bar click Run | Run
Program.

5 Review the Results.

Use the Navigation Tree to display the results.

6 Save the input data at any time.

On the toolbar, click the Save button, or on the menu bar click File | Save.

7 Print a hard copy of the results, if desired.

On the toolbar, click the Print button or on the menu bar click File | Print.
In the dialog box, check the boxes next to the desired output, and click Print.

8 Update the file with current geometry.

On the menu bar click Run | Update file with Geometry.
9 Transfer design information to other programs, if desired.
On the menu bar click Run | Transfer. In the dialog box, check the box next
to the desired program and click OK.

10 Exit Aspen EDR.

On the menu bar click File | Exit. The program prompts you to save changes.
Click the appropriate button.
The Aspen EDR Program Window
 Title Bar
The bar at the top of the window displays the current program and file name.
Use the Minimize and Maximize and Restore screen control button to change
the size of the program window and return the window to the original
settings. The Close button closes the active program or file.
 Navigation Tree, Forms and Sheets
Each Aspen EDR program has a Navigation Tree which appears in the left
pane of the program window. The tree is organized by Input and Results
folders that contain program-specific forms.
Expand the folders to display the forms. Use the scroll bar to scroll through
the forms.
Each form contains one or more sheets for entering data in various input
fields or for reviewing results. Tabs display the names of the different sheets.
To display a sheet, click on the appropriate tab.
 Prompt Area and Status Bar

This Prompt area in the Program window provides information to help you
make choices or perform tasks. It contains a description about the current
input field.
The Status bar at the bottom of the main Aspen EDR window displays
information about the current program status and input field status. If value
entered for an input field is outside the normal range, a warning will be
display in the Status Bar with the recommend value limits.
 Key Functions
Key Description

F1 Activates the Help system

Moves the location of the

cursor within an input field
Arrow Keys
and scrolls through the
options in a given list

Deletes the character at

the current cursor position
Delete Key
and shifts the remainder
of the input

Returns the cursor to the

Home Key
beginning of the input field

Moves the cursor to the

End Key
end of the input field

Scrolls the user through

Forward Tab Key
the input fields of a form

Move cursor back to

Backward Tab Key
previous field

Erases the characters

Control + Delete from the cursor position
Keys to the end of the input
field

Scrolls the user through

Page Up/Page
the forms of the Menu
Down Keys
Tree

Deletes the character to

the left of the current
Backspace Key
cursor position in an input
field
 Mouse Functions
In the following descriptions, “click” means to place the mouse pointer on the
item and press the left mouse-button.
Location Action

Click the appropriate menu to

Menu Bar display the choices; then click the
desired option

Toolbar Click the desired toolbar button

Click the desired form in the Menu

Forms
tree

Click the desired tab at the top of

Sheets the form to move between the
sheets.

Click the desired input field.

List items: click the arrow key to
the right of the input field to display
the items, then click the desired
Input Fields
option on the list
Checkbox: click the checkbox to
toggle between selecting and
clearing the checkbox.

Scroll Page
Click the up direction arrow
Up

Scroll Page
Click the down direction arrow
Down

Click the input field that you need

help, and then select the F1 key.

Help For "What's This" help, click the "?"

button on the toolbar. Then point
to the input field that you need help
on and click.
 Menu Bar
The program has a number of additional features that can be accessed
through a menu bar at the top of each screen. Using the left mouse button,
click on a menu name to see the pull down options available. Click on a
desired option or press the “Alt” key and the underscored character shown
(some options can be accessed by a given “Ctrl” key + letter combination).
See Also
File Menu
Edit Menu
Run Menu
Tools Menu
View Menu
Window Menu
Help Menu
 File Menu
Option Description

New (C trl+N) Opens new file for desired Aspen EDR program

Open (C trl+O) Opens existing Aspen EDR program file

C lose C loses a chosen Aspen EDR program window

Add Application Opens a chosen Aspen EDR program window

Remove
Removes a chosen Aspen EDR program window
Application

Save (C trl+S) Saves current file under chosen filename

Save As Saves current file as a different filename

Import physical property data from a pre-existing PSF file or from

Import From
a pre-existing Aspen HYSYS case file

Export To Export results to Excel, a DXF file, a RTF file, or a DOC file

Print Setup Allows for change to printing options

Print (C trl+P) Prints desired results sections from Aspen EDR program

Description Displays the contents of the Description field in the input file

Exit Exits Aspen EDR program and return user to Windows

 Edit Menu
Option Description

Undo Undoes the last edit operation.

C ut (C trl+X) Deletes the highlighted text.

C opy (C trl+C ) Saves a copy of the highlighted text.

Paste (C trl+V) Paste inserts text from a copy to directed location

 Run Menu
Option Description

Run “Program” Runs a chosen Aspen EDR program

Stop Stops the run of a chosen Aspen EDR program

Transfer Transfers design information into another EDR program

Update Updates file with final design information

 Tools Menu
Option Description

Provides access to units of measure, chemical database

Data Maintenance
reference, material database, and C osting database.

Program Settings Default units setting and headings for drawings

Security Access to Aspen EDR security program.

Sets language to English, French, German, Spanish or Italian

Language
(C hinese and Japanese to be offered in a later version).

Plot Plots results functions.

Add C urve Allows the addition of another curve to an existing plotted curve
 View Menu
Option Description

Tool Bar Shows or hides the Tool Bar

Status Bar Shows or hides the Status Bar

Zoom In Enlarges sections of the Aspen EDR drawings

Zoom Out Returns drawings to normal size

Refresh Refreshes screen

Variable List Displays variable list for form

 Window Menu
Name Description

Arranges program windows one behind the

C ascade
other

Tile Horizontal Arranges program windows one on top another

Arranges program windows one besides the

Tile Vertical
other

Arrange Icons Automatically arranges icons

C reate C reates a window for a Aspen EDR program

 Help Menu
Name Description

C ontents Open Aspen EDR help table of C ontents

Search for Help Displays a list of topics for detailed help

What’s This Allows the user to place “?” on desired item to receive information
Help about the item

Training Direct access to the AspenTech Training web site

Support Direct access to the AspenTech Support web site

About EDR Provides information on the current Aspen EDR release

 Main Toolbar

Icon Description

Creates a new Aspen EDR

New
program file

Opens an existing Aspen

Open
EDR program file

Save Saves the current file data

Opens the Shell&TubeMech

Shell&TubeMech
program window

Opens the Props program

Props
window

Opens the Ensea tube

Ensea
layout window

Opens the Qchex budget

Qchex
costing window

Opens the Shell&TubeMech

Shell&TubeMechc
Component design window

Opens the Metals property

Metals
database window

Runs the chosen Aspen

Run
EDR Program

Enlarges sections of the

Zoom In
Aspen EDR drawings

Returns sections of
Zoom Out
drawings to normal size

Plot Plot results functions

What’s This? Allows user to place “?” on
desired item to display
information about the item
 Zoom In/Zoom Out
You can Zoom In or Zoom Out on selected sections of the Aspen EDR
drawings by selecting an area and drawing a frame around it.
To draw the frame, select a frame corner, press and hold down the left mouse
button and drag the cursor diagonally to the opposite corner and then release
the mouse button.
Click the Zoom In button to resize the framed section to the full window size.
 Program Toolbar

Icon Description

Allows quick access to forms in the Menu

Navigator
Tree

One Level Takes the user up one level in the Menu

Up Tree

Hide Folder
Hides Navigator Menu Tree
List

Allow you to change globally the units of

Units Box
measure

Takes the user to the most recently

Go Back
viewed form

Takes the user to the next form in the

Go Forward
Menu Tree

Previous Takes the user to the previous form in

Form the Menu Tree

Takes the user to the next form in the

Next Form
Menu Tree

Takes the user to the next required

Next
input or result sheet
 Next
The Next button guides you sequentially through the required input forms to
complete the input for the problem. Note that subsequent steps are
dependant upon your previous selections in the program. When you use the
Next button, the program minimizes the input information required and uses
program defaults.
 Units of Measure
You can access the Units of Measure by selecting Tools in the Menu Bar and
then selecting the Data Maintenance section. You can set the default units of
measure to US, SI, or Metric and also set up your own customized set of
units. In the Units Maintenance section you can customize the conversion
factors used and the number of decimal point shown in the results.
 Heat Exchanger Standards
This function allows you to create a database with your standard exchanger’s
sizes that can reference from the EDR design programs.
 Chemical Databank (Aspen EDR Props & Private
Chemical Databank)
This item provides access to the Aspen EDR Props, chemical databank, and
Private Chemical Databank, the user private property databases. The Private
Chemical Databank program allows you to build your own private property
databank that can be accessed from Props. Reference the Private Chemical
Databank section of this manual for additional information.
 Materials Databank (Aspen EDR Databank &
Private Materials of Construction Databank)
This item provides access to the Aspen EDR Metals, material databank, and
Private Materials of Construction Databank, the private property metals
databases. The Private Materials of Construction Databank program allows
you to build your own private property databank that can be accessed from
the Shell&Tube, AirCooled, and Shell&TubeMech programs. Reference the
Private Materials of Construction Databank section of this manual for
additional information.
 Materials Defaults (Defmats)
This item provides access to the ASPEN EDR Defmats, material defaults
database for metals in the databanks. The Defmats program allows you to
change the specified material specifications to be used when the generic
material references are specified.
 Costing (Exchanger Costing Database)
This item provides access to the Exchanger Costing Database fabrication
standards and material pricing databases. Labor, fabrication standards, and
material pricing may be customized your applications. For more information,
see the Exchanger Costing Database section of this manual.
 Frequently Used Materials and Chemical
Components
You can set a list of frequently used materials and/or chemical components
for the databank search engines. This will allow searching for a material or
component from your personalized list of items you use often.
 Program Settings
You can specify global program settings, which all EDR programs can use.
These global settings are available from the Tools menu. They include:
File Save Options
Set the auto-save file functions. You can set the program to save your file
information every few minutes or at the time the program is executed.
Company Logo
By providing the reference to a Bitmap file, you can add your company logo to
the program results and drawings.
Default Units of Measure
You can set the default units of measure to US, SI, or Metric. Note that the
units may be changed at any time in the Aspen EDR program window.
Headings / Drawing Title
You can set up the default headings and title block information that appears
on the printed output and drawings.
Nozzle size specification on drawings
You can set the units set basis for the nozzle sizes shown on the drawings.
For example, US unit size nozzles can be shown even though the drawings
are in SI or metric units.
Folder for customized database files
You can specify a folder location for your customized database files. The
Aspen EDR programs will then reference your customized database files in the
specified folder in lieu of the standard database files in the program PDA
folder.
Excel templates
You can specify an Excel template file to use for each program as a default.
When you select File | Export | Excel, the specified default template is used.
Heat exchanger standards
You can set which exchanger standards database file is to be referenced.
Advanced
You can enable variable attributes so they will be shown in the Aspen EDR
program prompt area. For example, set drag-drop format to move data to
Excel; set the maximum disk space for temporary files.
 Input Fields
Sheets are made up of input fields and their descriptions. For each field, the
user (1) enters data, (2) chooses from a given list of options, or (3) checks
the cell if appropriate. The cursor can be moved from one input field to
another by using the Tab key, Enter key, arrow keys, or the mouse.
You can navigate through an input form by using the Tab key or Enter key
which will take you to the next required input field or you can select the items
with the mouse. To navigate through an input field grid, such as for physical
properties, or nozzle connections, you can use the Enter key which will move
the cursor down to the next field in a column, or you can use the arrow keys
to direct the cursor, or you can use the mouse to select the input field.
The input fields consist of the following types:
User defined. You enter the value such as a temperature or operating
pressure.
User defined with suggested values. You can input a value or select from
a list of typical values for the input which are available in a drop down
selection menu. You can access by the drop down menu by clicking on the
input field with the mouse and then select the down arrow displayed. You can
select an item in the drop down menu by using the up and down arrow keys
or by selecting with the mouse.
Available program selections. You select from a drop down menu list or
options list displayed on the input form. You can select an item in the drop
down menu by using the up and down arrow keys or by selecting with the
mouse.
Many of the input fields have graphical support. As you select from the
available menu options, a sketch of the selection will appear next to the input
field.
There are two types of data that can be entered: alphanumeric and numeric.
Alphanumeric fields accept any printable character. Numeric fields accept only
the digits zero through nine plus certain special characters such as: + - .
You can enter letters of the alphabet in either upper case or lower case. The
letters are retained in the case entered for headings, remarks, and fluid
names.
Whole numbers can be entered without a decimal point. Numbers over one
thousand should not have punctuation to separate the thousands or millions.
Decimal numbers less than 1 may be entered with or without the leading
zero. Scientific notation (E format) can be used.
Examples of Valid Examples of
Entries Invalid Entries

125 15/16

289100 289,100

-14.7

0.9375

If an input field is identified as optional input (white background), you may

leave the field blank and the program will use a default value. For physical
properties where you want the program to retrieve the value from the
physical properties databank (see Search a Databank), you should leave the
input field blank. In many cases, you can get additional descriptive
information on an item by pressing F1, the Help key.
Required input fields will be identified by a green background color for the
input field. Optional input fields will have a white background. Any inputted
value that exceeds a normal range limit will be highlighted with a red
background. Note that the program will still accept and use a value outside
the normal range. If a folder or tab is not complete, a red X will be shown on
the respective folder in the Navigation Tree and on the Tab label.
 Units of Measure - Field Specific
All of the Aspen EDR programs run in traditional U.S. units, SI units, and
traditional metric units. The global setting for units is set in the Units Box
located in the Tools Bar.
The programs allow you to dynamically change the system of measure used in
the input or results sections. It is therefore possible to view and/or print the
same solution in two different systems for easy comparison or checking.
Field specific units of measure control is also available. A specific set of units
may be specified for each input data field by selecting from the units drop
down menu next to the input field. The field specific units will override the
global units set in the Units Box.
You can input the value in one set of units and then select an alternate unit
from the drop down units menu, and the input value will be converted.
Please note that the solution of a design problem may be dependent upon the
system of measure used in the input. This is due to differing standards in
incrementing dimensions. This is especially true for the mechanical design
programs.
 Databank Reference
You can search for an item in the Chemical Component or Material of
Construction Databanks. Click on the Search button located on databank
reference form to open the search utility.
To find an item in the list, type in the first few letters of the material name.
Or, scroll through the material list using the up and down arrows to the right
of the field. You can also specify a search preference, database, material class
and material type. Click on the desired material. In the Component list, click
on the desired component and press Set to match it with the selected
reference. You can also erase a reference from the component list by clicking
on the component and pressing Clear.

The components in the databank have a component name which is up to 32

characters long, a chemical formula or material specification. You use these
for the databank reference. We recommend that you do not use the chemical
formula, because the formula may not be a unique reference. You should use
the appropriate reference exactly as it appears in the databank directory.
 Range Checks
After data is entered in an input field, the program will check the specified
data against a high and low value range. If a value falls outside this range,
the input field will turn red and a warning message will be displayed at the
bottom left hand of the screen. This does not mean the program will not
accept this data. It merely suggests that you should check the data for
accuracy. If the data is correct, continue with data input.
 Change Codes
Several of the programs have a form for change codes. You can use this form
to insert four letter codes and numeric values to specify input data which is
not included in the regular input screens. Refer to the Change Code section in
the individual Program Guide. First type the change code, then an equals sign
(“=”), then the numeric value. For example: SENT=2.
It also possible to provide a Super Change Code by defining the change
codes to be applied to a design in a separate ASCII file and referencing the
file as follows in the Change Code input field: File="Filename"
 The Database Concept
We suggest that you use the same input file for all Aspen EDR programs for a
specific heat exchanger design problem. Save the input data in a convenient
filename that can be accessed by all the Aspen EDR programs.
Using the Transfer function under the Run menu, you can add data to the
input for use with other programs. For example, you can use Shell&Tube to
thermally design a shell and tube heat exchanger, and then request that the
chosen design be transferred to another program such as Shell&Tube into
AirCooled, Shell&Tube into Shell&TubeMech, or Shell&TubeMech into Ensea.
In this way the appropriate design data is directly available to other
programs.
This concept also makes it easy for you to compare design solutions in
different types of heat exchangers. You can run Shell&Tube to design a shell
and tube heat exchanger and then, with very little additional input data, run
AirCooled to design an air-cooled heat exchanger.
 Program Output
The primary output formats of the Aspen EDR programs are:
Display
Print
Drawings
Display
Scroll through the forms in the Results folder of the navigation tree to
evaluate the results of the program output. Each form may have multiple
sheets, which you can display by clicking on the different tabs.
Print
To print the results, choose Print from the File menu. On the Print dialog box,
review the printing options, make any desired changes, and click OK.
Drawings
2D CAD
The output of many Aspen EDR programs includes drawings. Drawings
generated by the Shell&TubeMech program may be exported to CAD programs
via a DXF file format.
3D Solid Model CAD
Shell&Tube Users can now create fully featured 3D solid models based on the
AutoDesk Inventor Tool, using the File | Export menu option. The interface
allows the user to create models of individual components, groups of
components, or the entire exchanger.
Shell&Tube 3D solid models provide a modern architecture from which the
user can create sophisticated 2D drawings. Some dimensions used in the 3D
Solid Model created from Shell&Tube are estimated for example, tubesheet
thickness. For a 3D Solid Model reflecting rigorous mechanical design
calculations results and fabrication practices use Shell&TubeMech. AutoDesk
Inventor software can import and export both the STEP and IGES file formats
as core functionality. It also supports the DWG, DXF™, and SAT (ACIS®)
formats as well as 3D Studio VIZ®, and 3ds max™ for output only. The
Inventor CAD program must be loaded on your system to generate the
drawings.
 Getting Help
The Aspen EDR software includes extensive help facilities, which have been
designed to minimize the need for printed documentation.
You may access the help facility in the following ways:
General Help
This level includes information that applies to all of the Aspen EDR programs.
You can access the general help index by selecting the Help button from the
Menu Bar at any time in the program. You may select the Help Contents to
select from the list of topics or you may search for Help on a specific topic.
Field-specific general Help topic
By selecting an input field with the mouse and then pressing the F1 key, the
general help will open and display the information.
Field-specific “What’s This?” Help
You can obtain input field specific help by selecting the What's This ? button
on the Tool Bar and then pointing to the input field and clicking the mouse to
display the information.
Training
From the Help menu, you can directly access the AspenTech Training web
site. The site provides the latest information on training sessions being
offered. You can also access Computer-Based Training sessions available for
the EDR programs.
Support
From the Help menu, you can directly access the AspenTech Support web site.
You can report support issues that will be reviewed by our technical support
team. You can also access our Knowledge Base support area - an information
source full of technical tips on using the EDR programs and answers to
frequently asked questions.
 Aspen HTFS Research Network

A new route to accessing AspenTech’s HTFS Research Network is being

developed. This is not yet fully functional. It will require a valid Research
Network SLM license as well as a user ID and password to access the
information held on the HTFS web site. If your company already has access to
the Research Network then you may continue to access through your Internet
Explorer at: http://www.aspentech.com/htfs/resnet/default.asp. You will
require your user ID and password.
If you do not currently have access or would like to know more, please
contact us at: mailto:[email protected]

The Research Network website makes a vast amount of accumulated

knowledge, on process heat transfer, readily available from the engineer's
desktop. Amongst the many resources available are:

HANDBOOK - a comprehensive reference to heat exchanger theory and

practice with step-by-step calculation procedures illustrated with worked
examples and concise reviews of equipment functionality and processes.
Methods are regularly updated from results of the research program.

DESIGN REPORTS - explaining the models behind the software and

including a special series detailing the methods used in individual computer
programs. Detailed derivation and comparisons of design methods; validation
of design procedures and description of the technical methods used in the
Aspen EDR programs

RESEARCH REPORTS - generated from our extensive and on-going research

program since 1971.

HTFS HEATFLO - a bibliographic reference database containing references to

over 90,000 high quality experimental and theoretical research papers in the
field of applied heat transfer and fluid flow relevant to the needs of the
chemical process and power industries.

In addition to what is available on the website, members of the Research

Network are also entitled to be nominated to participate on the Review Panels
where they can learn about our latest plans for research and software
development and provide their valuable feedback. Feedback from all members
is obtained through an annual questionnaire.
Searching
Most of the content can be searched via the Google search box in the top
right hand corner of the web page.

Research Facilities
AspenTech works in partnership with leading research institutions and
universities. Experimental facilities include industrial size boiling and
condensation rigs, wind tunnels, and test facilities for obtaining thermal
hydraulic characteristics of compact and other advanced heat exchangers.

Benefits
Improved design – HTFS Research Network members have direct access to
the leading-edge research carried out by acknowledged world experts in heat
exchange. It also enables full understanding of the heat exchange models,
assumptions and correlations used within AspenTech's heat exchanger
software, to help ensure quality designs.
According to one customer: "The combination of HTFS in-house research
coupled with their contacts with the worldwide academic community gives us
confidence that they are developing leading edge software for use by
ourselves and our contractors. Being members of the Research Network and
participation in the review panels gives us the assurance that the research
and software programs are relevant to our needs."
 Shell&Tube Thermal Design of Shell & Tube
Heat Exchangers
Shell&Tube Input
Shell&Tube Results

Shell&Tube Getting Started Guide

Shell and Tube Heat Exchanger Geometry

Quick Guide to Geometry Selection

 Shell&Tube Input
Problem Definition
Headings/Remarks
Application Options – Calculation Mode, Fluid allocation, Application Types,
Equipment Types
Process Data – Temperatures, Pressures, Flows, Quality, Pressure Drops,
Fouling, Heat Load

Physical Property Data

Stream Composition
Stream Properties – Property Databanks, Stream Definition, Property Tables

Exchanger Geometry
Geometry Summary – Geometry, Tube Layout
Shell/Heads/Flanges/Tubesheets – Shell/Heads, Covers, Tubesheets, Flanges
Tubes – Tube, Low Fins, Longitudinal Fins, Inserts, KHT Twisted Tubes
Baffles/Supports – Baffles, Tube Supports, Longitudinal Baffles, Variable
Baffle Pitches
Bundle Layout – Layout Parameters, Layout Limits/Pass Lanes, Tie
Rods/Spacers, Tube Layout
Nozzles – Shell Side Nozzles, Tube Side Nozzles, Domes/Belts, Impingement
Thermosiphon Piping – Thermosiphon Piping, Inlet Piping Elements, Outlet
Piping Elements

Construction Specifications
Materials of Construction – Vessel Materials, Cladding/Gasket Materials, Tube
Properties
Design Specifications

Program Options
Design Options – Geometry Options, Geometry Limits, Process Limits,
Optimization Options
Thermal Analysis – Heat Transfer, Pressure Drop, Delta T, Fouling
Methods/Correlations – General, Condensation, Vaporization, Enhancement
Data
Calculation Options – Calculation Options
 Shell&Tube Problem Definition
The Problem Definition section includes the following screens:
Headings/Remarks
Application Options and Application Control
Process Data
 Shell&Tube Headings/Remarks
The Headings/Remarks section includes the following screens:
TEMA Specification Sheet Descriptions
 Shell&Tube Application Options
The Application Options screen contains the following inputs:

General
Calculation Mode
Location of Hot Fluid
Select Geometry based on this Dimensional Standard
Calculation Method

Hot Side
Application
Condenser Type
Simulation Calculation

Cold Side
Application
Vaporizer Type
Simulation Calculation
Thermosiphon Circuit Calculation
 Shell&Tube Process Data
The Process Data screen contains the following inputs:
Fluid Name
Mass Flow Rate
Temperature
Vapor Mass Fraction
Operating Pressure
Pressure at Liquid Surface in Column
Heat Exchanged
Exchanger Effectiveness
Adjust if Over-Specified
Estimated Pressure Drop
Allowable Pressure Drop
Fouling Resistance

See Also:
Process Data Cross-Checking
 Physical Property Data Overview
For each stream within the exchanger there are two input sections:
Composition
Properties

Within the Composition section, the Physical Property Package (Properties

Data Source) can be selected.
The following property package options are available:
Aspen Properties
COMThermo
B-JAC Databank
You can also supply the properties data yourself: User Specified Properties
Some programs have a variation of user specified properties:
User Specified Properties with Heat Load
Two other options are shown to indicate when the properties data have been
generated by a process simulator. These are not facilities for generating
properties with the stand-alone program:
Aspen Plus
HYSYS

The selection of the property package will dictate what subsequent inputs are
requested and what screens may be displayed. The property package input
will indicate where physical properties have come from or where they will be
coming from.
The basic physical properties will consist of one to five data sets of stream
properties at various temperature points which should encompass the
operating temperatures of the exchanger. Each data set would represent a
different operating pressure. It is recommended that multiple data sets at
different pressure be used for applications involving changes of phase or gas
only since the pressure change through an exchanger can significantly impact
the properties and heat release curves for these applications. Data at two
pressures are adequate for most exchangers, with more only needed when
the pressure change in the exchanger is a significant fraction of the inlet
pressure.
The Properties section includes the following screens:
Properties
Phase Composition
Component Properties
Properties Plots

See also:
Non-Newtonian Fluids
Refrigerant Cross Referencing Table
 Physical Property Data Aspen Properties
If Aspen Properties is used, the properties will be generated when the
application is executed or when the user clicks the “Get Properties” button on
the physical properties screen. All properties will be retrieved and placed in
the input fields. For these property packages, an additional table for each
pressure level will be generated containing the mole fraction compositions of
each component in the vapor, liquid, and liquid 2 phases. In addition, some
applications may include a table of physical properties for each of the
individual components in the stream.

The Aspen Properties option includes the following screens:

Composition
Property Methods
Advanced Options
 Physical Property Data COMThermo
If COMThermo is used, the properties will be generated when the application
is executed or when the user clicks the “Get Properties” button on the
physical properties screen. All properties will be retrieved and placed in the
input fields. For these property packages, an additional table for each
pressure level will be generated containing the mole fraction compositions of
each component in the vapor, liquid, and liquid 2 phases. In addition, some
applications may include a table of physical properties for each of the
individual components in the stream.

The COMThermo option includes the following screens:

Composition
Property Methods
Interaction Parameters
Advanced Options
 Physical Property Data B-JAC
If B-JAC is used, the properties will be generated when the application is
executed or when the user clicks the “Get Properties” button on the physical
properties screen. All properties will be retrieved and placed in the input
fields. For these property packages, an additional table for each pressure level
will be generated containing the mole fraction compositions of each
component in the vapor, liquid, and liquid 2 phases. In addition, some
applications may include a table of physical properties for each of the
individual components in the stream.
The B-JAC Databank option includes the following screens:
Composition
Property Methods
Interaction Parameters
NRTL
Uniquac
Advanced Options
 Physical Property Data User Specified
Properties
If User Specified Properties is specified, you will be expected to input the
physical properties of the stream yourself, either directly, or by copying them
from a spreadsheet. The main properties required are exactly those that could
be generated by a properties data bank, and you can supply data at one or
more pressure levels.
A useful option is to retrieve properties from Aspen Properties, COMThermo,
or B-JAC Databanks and then switch to User Specified properties. The
properties present in the input fields will remain, and you could then
selectively change those properties, if you needed to.
 Physical Property Data Aspen Plus
The Aspen Plus option will normally be set when the property tables have
been populated by either of the process simulators. When these options are
set, the properties are NOT retrieved each time the program executes. The
properties will remain as specified unless the user chooses to overwrite them.
See Also
Physical Property Data Import from
 Physical Property Data HYSYS
The HYSYS option will normally be set when the property tables have been
populated by either of the process simulators. When these options are set, the
properties are NOT retrieved each time the program executes. The properties
will remain as specified unless the user chooses to overwrite them.

See Also
Physical Property Data Import from
 Physical Property Data Properties
EDR programs obtain physical property data by interpolating between sets of
physical property data obtained or specified at several different pressure
levels. This stream data may either be input directly on the Property Table
screen, exported from a process simulator such as Aspen Plus or HYSYS or
retrieved from one of three different physical property packages: Aspen
Properties, COMThermo, or B-JAC, or be provided directly as input.
A set of stream property data contains values of density, specific heat,
viscosity and thermal conductivity for liquid and/or vapor phases as
appropriate, together with specific enthalpy and quality (vapor mass fraction).
For two phase streams, surface tension may also be supplied.
For two phase-streams a set of stream data comprises a set of liquid data, a
set of T-h-x data and a set of vapor data. Data for a second liquid phase can
also be supplied when this is present, together with the mass fraction (within
the stream) of this second phase.
Data for each phase should only be provided when that phase is present. Data
for vapor at the dew point and liquid at the bubble point should also be
provided when possible, since this is useful when interpolating data near
those points. The exception is pure component streams, where the bubble and
dew point are the same. Vapor data at the bubble point and liquid data at the
dew point should preferably not be included.
For single phase streams, only the properties for the relevant phase are
needed. If you are supplying the data, T-h-x data re optional, but are optional
when enthalpies can be evaluated from specific heats.
If you supply the data, you can provide each set at up to 24 points, but more
than 12 are rarely necessary. One or two points are acceptable if this is all
you have, but this may limit the accuracy of the calculations. Temperature
points you supply can be in any order but to facilitate plotting it is recommend
that they be placed in either increasing or decreasing order.
For two-phase streams, bubble and dew points are very important. If either of
these points is within the range of temperatures you supply for T-h-x data,
then this point should be added to any T-h-x data you are supplying. They can
be added on the end, as the order of input of temperatures is unimportant. If
these points are just outside the range of data supplied, it can still be useful
to add them in, as this will remove the need for the program to estimate
them.
Temperature points need not correspond exactly to exchanger inlet and outlet
conditions, but it is clearly sensible that they cover a similar temperature
range, or there may be a loss of accuracy associated with extrapolation.
A data set, block of Stream Property data must relate to a single pressure.
More than one data set per stream, at different pressures, may be supplied if
pressure dependence of properties is important. The data can be input in any
of the standard sets of units for stream data.
You can set up the main stream input data with properties in it in a number of
ways, either by using the Aspen properties, COMThermo or B-JAC databanks
supplied with the program, or by typing/copying in the information yourself,
or by importing information, which has been set up previously in the correct
format by a Process Simulator program.
See also:
Pressure Levels
Non-Newtonian Fluids - Data Input
 Physical Property Data Phase Composition
The Phase Composition tab contains a table with the vapor, liquid, and 2nd
liquid phase mole fraction compositions of each component in the stream at
each temperature point. The table displayed corresponds to the pressure level
currently set on the Physical Properties tab. To see a composition table at
other pressure levels, the current pressure level must be reset to the desired
data set.
 Physical Property Data Component Properties
The component properties tab contains a table of component properties.
Molecular weight is the main parameter used at present. Other will in future
be used in some of the more advanced heat transfer calculation methods.
These properties will always be retrieved from the Aspen Properties,
COMThermo, or B-JAC properties packages when they are used. These
properties cannot be directly specified by the user.
 Physical Property Data Properties Plots
The stream physical properties shown in the grid on the properties tab can be
seen plotted on the Plots tab. Each pressure level data set is shown separately
so the affect of pressure on the selected property can be analyzed. All
properties can be plotted against temperature or enthalpy. Various tools at
the top of the plot screen are available for selecting plot sections to zoom on,
locate specific points on the plot, saving the plot to a file, or printing.
 Shell&Tube Exchanger Geometry
The Exchanger Geometry section includes the following screens:
Geometry Summary
Shell/Heads/Flanges/Tubesheets
Tubes
Baffles/Supports
Bundle Layout
Nozzles
Thermosiphon Piping
 Shell&Tube Geometry Summary
The Geometry Summary section includes the following screens:
Geometry
Tube Layout
 Shell&Tube Shell/Heads/Flanges/Tubesheets

The Shell/Heads/Flanges/Tubesheets section includes the following screens:

Shell/Heads
Covers
Tubesheets
Flanges
 Shell&Tube Tubes
The Tubes section includes the following screens:
Tube
Low Fins
Longitudinal Fins
Inserts
KHT Twisted Tubes
Internal Enhancement
 Shell&Tube Baffles/Supports
The Baffles/Supports section includes the following screens:
Baffles
Tube Supports
Longitudinal Baffles
Variable Baffle Pitches
Deresonating Baffles
 Shell&Tube Bundle Layout
The Bundle Layout section includes the following screens:
Layout Parameters
Layout Limits/Pass Lanes
Tie Rods/Spacers
Tube Layout
Pass Details

See also
Tube Layout: Overview
Tube Bundle Layout: How to get what you want
New Tube Layout Calculations
 Shell&Tube Nozzles
The Nozzles section includes the following screens:
Shell Side Nozzles
Tube Side Nozzles
Domes/Belts
Impingement
 Shell&Tube Thermosiphon Piping
The Thermosiphon Piping section includes the following screens:
Thermosiphon Piping
Inlet Piping Elements
Outlet Piping Elements

See Also:
Thermosiphons
 Shell&Tube Construction Specifications
The Construction Specifications section includes the following screens:
Materials of Construction
Design Specifications
 Shell&Tube Materials of Construction
The Construction Specifications section includes the following screens:
Vessel Materials
Cladding/Gasket Materials
Tube Properties
 Shell&Tube Design Specifications
The Design Specifications section includes the following screens:
Design Specifications
 Shell&Tube Program Options
The Program Options section includes the following screens:
Design Options
Thermal Analysis
Methods/Correlations
Calculation Options
 Shell&Tube Design Options
The Design Options section includes the following screens:
Geometry Options
Geometry Limits
Process Limits
Optimization Options
 Shell&Tube Thermal Analysis

The Thermal Analysis section includes the following screens:

Heat Transfer
Pressure Drop
Delta T
Fouling
 Shell&Tube Methods/Correlations
The Methods/Correlations section includes the following screens:
General
Condensation
Vaporization
Enhancement Data
Hetran Condensation Model – Contran
 Shell&Tube Calculation Options
The items on this sheet let you specify whether to use the Standard or
Advanced calculation method, and to select various options available with the
Advanced method:

Calculation Method

Convergence Options
Maximum Number of Iterations
Convergence Tolerance - Heat Load
Convergence Tolerance - Pressure
Relaxation Parameter
Calculation Grid Resolution
Convergence Criterion
Calculation Step Size

Pressure Drop Options

Pressure drop calculations options - cold side
Pressure drop calculations options - hot side

Multiplier for Number of Tube Passes

 Shell&Tube Results

Input Summary

Result Summary
Warnings & Messages
Optimization Path
Recap of Designs
TEMA Sheet
Overall Summary

Thermal / Hydraulic Summary

Performance – Overall Performance, Resistance Diagram
Heat Transfer – Heat Transfer Coefficients, MTD & Flux, Duty Distribution
Pressure Drop – Pressure Drop, Thermosiphon Piping, Thermosiphon Piping
Elements
Flow Analysis – Flow Analysis, Thermosiphons and Kettles
Vibration & Resonance Analysis – Fluid-Elastic Instability, Resonance
Analysis, TEMA Fluid Elastic Instability, TEMA Amplitude and Acoustic Analysis
Methods

Mechanical Summary
Exchanger Geometry
Setting Plan
Tubesheet Layout
Cost / Weights

Calculation Details
Analysis along Shell
Analysis along Tubes
Analysis for X and K shell
 Shell&Tube Input Summary
This section provides you with a summary of the information specified in the
input file.
It is recommended that you request the input data as part of your printed
output so that it is easy to reconstruct the input, which led to the design.
 Shell&Tube Result Summary
The Result Summary section includes the following screens:
Warnings & Messages
Optimization Path
Recap of Designs
TEMA Sheet
Overall Summary
 Shell&Tube Warnings & Messages
Aspen Shell & Tube Exchanger provides an extensive system of errors,
warnings and other messages to help you use the program. They are for the
most part self explanatory, and contain information on the values of
parameters which have led to the reported condition. There are several
hundred messages built into the program, and these can be divided into
number of types.
Range Checking Warning.
These relate to input values which are outside the range of what is normally
expected. You should check that the input value referred to is correct. If so
the message can usually be ignored, though for unusual exchanger
geometries, or unusual fluid properties, it is likely that the uncertainty in the
results is exacerbated.
Input Omission Error
These identify input parameters which are necessary for the program to run.
Whether a particular parameter is necessary can depend on the values of
other parameters. Required input is normally identified in the User interface,
though there are occasionally instances where a required item is not
highlighted in the Interface, or where an item is shown as required by the
interface, does not lead to an error when the program is run.
Range Checking Error
These identify input values which are beyond the range of what is permitted.
They cause program execution to cease.
Results Warning
The run has completed, but problems have been identified with some part of
the calculation, which indicate that some aspect of the results may be subject
to more uncertainty than normal.
Results Error
The run has either failed to generate a significant part of the results, or failed
to complete in some way that many of the results given should not be relied
on.
Operation Warning
The run has completed, but is predicting operation which does not meet
normal practice, or is in some other way inadvisable, or in extreme cases
impracticable.
Advisory
There is some feature of the exchanger, or its operation which is unusual, and
for which better alternatives may exist.
Notes
Any other information which may be useful.
 Shell&Tube Optimization Path
This part of the output is the window into the logic of the program. It shows
some of the heat exchangers the program has evaluated in trying to find one,
which satisfies your design conditions. These intermediate designs can also
point out the constraints that are controlling the design and point out what
parameters you could change to further optimize the design.
To help you see which constraints are controlling the design, the conditions
that do not satisfy your specifications are noted with an asterisk (*) next to
the value. The asterisk will appear next to the required tube length if the
exchanger is undersurfaced, or next to a pressure drop if it exceeds the
maximum allowable.
In design mode, Shell&Tube will search for a heat exchanger configuration
that will satisfy the desired process conditions. It will automatically change a
number of the geometric parameters as it searches. However Plate will not
automatically evaluate all possible configurations, and therefore it may not
necessarily find the true optimum by itself. It is up to the user to determine
what possible changes to the construction could lead to a better design and
then present these changes to the program.
Shell&Tube searches to find a design that satisfies the following:
(1) enough surface area to do the desired heat transfer
(2) pressure drops within the allowable
(3) physical size within acceptable limits
(4) velocities within an acceptable range
(5) mechanically sound and practical to construct
In addition to these criteria, Shell&Tube also determines a budget cost
estimate for each design and in most cases performs a vibration analysis.
However cost and vibration do not affect the program's logic for optimization.
There are over thirty mechanical parameters which directly or indirectly affect
the thermal performance of a shell and tube heat exchanger. It is not
practical for the program to evaluate all combinations of these parameters. In
addition, the acceptable variations are often dependent upon process and cost
considerations which are beyond the scope of the program (for example the
cost and importance of cleaning). Therefore the program automatically varies
only a number of parameters which are reasonably independent of other
process, operating, maintenance, or fabrication considerations.
The parameters which are automatically optimized are:
shell diameter baffle spacing pass layout type
tube length number of baffles exchangers in parallel
number of tubes tube passes exchangers in series
The design engineer should optimize the other parameters, based on good
engineering judgment. Some of the important parameters to consider are:
shell type tube outside diameter impingement protection
rear head type tube pitch tube pattern
nozzle sizes tube type exchanger orientation
tubesheet type baffle type materials
baffle cut fluid allocation tube wall thickness
 Shell&Tube Recap of Designs
The Recap of Design screen summarizes the basic geometry and
performance of all designs reviewed up to that point. The side-by-side
comparison allows you to determine the effects of various design changes and
to select the best exchanger for the application.
As a default, the recap provides you with the same summary information that
is shown in the Optimization Path.
You can recall an earlier design case by selecting the design case you want
from the Recap list and then clicking the Select Case button. The program
then regenerates the design results for the selected case.
You can customize what information is shown in the Recap by clicking
Customize. The Recap Customizing screen displays all available fields on
the left-hand side and all currently selected fields on the right-hand side. Use
the buttons to change which fields are displayed.
If you want to save your selection, enter a name into the Recap list name
input then click the Save List button. For subsequent runs, you can select
your customized list from the Available recap lists drop-down box. The
customized list will be stored in a file called HTFS_User_Recap.xml which
will be located in the folder designated for customized database files (Tools |
Program Settings | Files).
See also:
Storage of Recap of Designs
 Shell&Tube TEMA Sheet
The TEMA sheet displays the results from the thermal calculations using the
standard datasheet detailed in TEMA standard and includes a basic Setting
Plan.
 Shell&Tube Overall Summary
The Overall Summary provides a concise summary of the inlet/outlet process
conditions of each stream as well as important criteria regarding, heat
transfer, pressure drop, velocities, temperature differences and heat loads.
This information can be used to quickly evaluate the overall performance of
the unit. A basic summary of the exchanger’s geometric configuration is also
provided so that other geometry options can be considered during the
analysis of the overall performance data.
 Shell&Tube Thermal / Hydraulic Summary
The Thermal / Hydraulic Summary section includes the following screens:
Performance
Heat Transfer
Pressure Drop
Flow Analysis
Vibration & Resonance Analysis
Methods
 Shell&Tube Performance
The Performance section includes the following screens:
Overall Performance
Resistance Distribution
Shell by Shell Conditions
Hot Stream Composition
Cold Stream Composition
 Shell&Tube Heat Transfer
The Heat Transfer section includes the following screens:
Heat Transfer Coefficients
MTD & Flux
Duty Distribution
 Shell&Tube Pressure Drop
The Pressure Drop section includes the following screens:
Pressure Drop
Thermosiphon Piping
Thermosiphon Piping Elements
 Shell&Tube Flow Analysis
The Flow Analysis section includes the following screens:
Flow Analysis
Thermosiphons and Kettles
 Shell&Tube Vibration & Resonance Analysis
The Vibration & Resonance Analysis section includes the following screens:
Fluid-Elastic Instability
Resonance Analysis
TEMA Fluid Elastic Instability
TEMA Amplitude and Acoustic Analysis
Vibration Tubes
 Shell&Tube Methods
The Methods Summary screen lists all the models and methods that have
been used by the program as part of the calculations.
 Shell&Tube Mechanical Summary
The Mechanical Summary section includes the following screens:
Exchanger Geometry
Setting Plan & Tubesheet Layout
Cost / Weights
 Shell&Tube Exchanger Geometry
The geometry used in the calculations is summarized in a series of screens:
Basic Geometry
Tubes
Baffles
Supports-Misc. Baffles
Bundle
Enhancements
Thermosiphon Piping
 Shell&Tube: Setting Plan & Tubesheet Layout
The Setting Plan & Tubesheet Layout section includes the following screens:
Setting Plan
Tubesheet Layout
U-Bend Schedule
 Shell&Tube Tubesheet Layout
The Tubesheet Layout details a scaled drawing of the Tube Layout as used as
part of the thermal calculations. No editing of the drawing is permitted as this
is an output view. To make changes to the Tube Layout refer to the
‘Exchanger Geometry – Geometry Summary – Tube Layout’ screen.

The tube layout diagram includes the following data:

Shell Side Inlet and Outlet Nozzles
Shell Cylinder (Shell Kettle Cylinder - if K Shell)
Tube Locations
Pass Partition Lanes
Baffles
Tie Rods
Impingement Plate
Sealing Strips
Bundle Runners
Longitudinal Baffle
Pass Partition Lane Sealing Strips

The following tables can be selected to view the data associated which each
item:
Bundle Limits
Pass Regions
Nozzles
Baffles
Tie Rods
Tube Lines
Impingement Plate
Sealing Strips
Bundle Runners
Longitudinal Baffle
Pass Partition Lane Sealing Strips
Click the left-hand mouse button to zoom in on an area of interest.

Click the right-hand mouse button to display a menu from which the following
options can be selected:
Draw tubes as circles
Draw tubes as crosses
Draw end tubes as circles
Draw border
Draw dimensions
Display titles

The Tubesheet Layout can be:

Printed
Copied to the clipboard
Saved as in file in the following formats: dxf, bmp, svg, wmf

See also:
Vibration Tubes
Tube Layout: Overview
 Shell&Tube Cost / Weights
This screen summarizes the weights calculated for the major components in
the exchanger, and includes an empty weight and a weight flooded with
water.
The total cost for the exchanger is also listed with a break down of the cost
into total labor and material.
 Shell&Tube Calculation Details
The Calculation Details section includes the following screens:
Analysis along Shell
Analysis along Tubes
Analysis for X and K shell

See Also:
Calculation Details for Axial Flow Shells
Calculation Details for Crossflow Shells
 Shell&Tube Analysis along Shell
The Analysis along Shell section includes the following screens:
Interval Analysis
Physical Properties
Plots

See Also:
Calculation Details for Axial Flow Shells
Calculation Details for Crossflow Shells
 Shell&Tube Analysis along Tubes
The Analysis along Tubes section includes the following screens:
Interval Analysis
Physical Properties
Plots

See Also:
Calculation Details for Axial Flow Shells
Calculation Details for Crossflow Shells
 Shell&Tube Analysis for X and K Shell
The Analysis for X and K shell section includes the following screens:
Interval Analysis

See Also:
Calculation Details for Axial Flow Shells
Calculation Details for Crossflow Shells
 Shell&Tube: Calculation Details for Axial Flow
Shells
The Calculation Details output provides a comprehensive overview of the
solution. There are tabulated values listing every calculation point, giving the
location of the point, and a number of important parameters at that point.
There are also facilities for plotting key parameters which can provide
valuable insights into what is happening in the exchanger.
The main “location” parameter for each calculation point is its distance along
the shell. The tube side pass number is also given, together with the shell
number, for handling multiple shells in series. The distance along the shell is
artificially increased (by just over one tube length) for each successive shell
in series, so that in the graphs of various parameters against distance, it is
clear which shell is which.
Each calculation point along the shell is numbered. In a four pass axial flow
shell, in the tube side table, each point number appears four times, and the
points are listed in order of flow along the four passes. The point number is
effectively an analogue of distance along the shell, but one which makes it
easy to compare information for different passes or to link shell side and tube
side information.
Among the parameters given at each point are
· the temperature of the fluid (tube side /shell side)
· the temperatures of the surface with which it is in contact (fouling
surface)
· the mean tube wall temperature (midway between the metal surfaces)
In the tube side table, both shell side and tube side temperatures are given.
In the plots, the default plot is of these two fluid temperatures against
distance along the exchanger. The plots will immediately indicate how
temperature differences vary along the exchanger and the location of any
temperature pinch. Changes in slope of the temperature curves will indicate
the location of dew or bubble points. It is easy to deduce flow directions from
the wall shell side and tube side temperatures change. In an E-shell, they will
indicate the shell side inlet end, and in split-flow shells, they will show what
difference, if any, there is between the performance in the two halves of the
exchanger.
The tube side table also gives information about both the tube side and shell
side heat transfer coefficients. At a given location along the exchanger, the
shell side coefficient can be different on different tube side passes because of
the different wall temperatures. The shell side table also gives coefficients,
but average values over all passes at each shell side point.
The plots for the tube side table also provide the opportunity to display both
tube side and shell side coefficients. For baffled shell side exchanger, there
will usually be a step change in shell side coefficient between the end spaces
and the main baffled region. For either shell side or tube side, changes in
coefficient at bubble or dew points may be visible.
The other parameters on the tube side table relate only to the tube side fluid,
while all those on the shell side table relate just to the shell side fluid. Nearly
all the parameters in the tabulated values can be plotted, and this is often the
most useful way of approaching the data. The data in the Calculation Details
tables is basically the same for all types of exchanger, but sometimes entire
columns are omitted when they are not relevant. For example quality and
void fraction are not output when the fluid is entirely single phase.
The Calculation Details for Crossflow Shells, which use a two dimensional
model of flow in each pass, are inherently more complicated.
 Shell&Tube: Calculation Details for Crossflow
Shells
For X-shells and K-shells, calculations are performed using a two-dimensional
grid of points for each crossflow pass, so at each calculation point (distance
along the shell), the Calculation Details table show multiple values at
different distances up the shell. These distances are measured from the shell
center (for consistency with the tube layout diagram), and are thus positive in
the top half of the shell and negative in the bottom half of the shell. The
number of points up the shell in each pass varies according to the number of
passes.
The plots of values in the Calculation details tables can also be plotted, but
since there are multiple values at each axial location, the plots are not as
straightforward to understand as for axial flow exchangers. With the
temperature given under tube side details, for example, the lines for the
calculated tube side temperature represent flows at various heights up the
pass. The lines for shell side temperatures on the same plot represent not the
flows but the shell side temperatures matching each tube side point. When
the tube side and shell side temperature ranges are well separated, the plots
are easier to understand than when the ranges overlap.
With shell side Calculation Details plots, temperatures and other parameters
appear as a set of vertical lines at each calculation point along the exchanger.
At each point, the range of values (at different distances up the shell) is clear,
but the way the values vary up the shell is not, and scrutiny of the tables may
be more useful than inspection of the plots.

See also:
Calculation Details for Axial Flow Shells
 Overview
The purpose of this example is to guide you through the design a simple
single-phase heat exchanger using Aspen Shell & Tube Exchanger
(Shell&Tube).

Contents:
Process Overview
Building the Simulation
Viewing the results
Properties from COMThermo
Creating a Checking Case

The Design calculation will determine the shell length and diameter, the
nozzle sizes, the number of tubes and passes, the number of baffles and
baffle cut. Other details such as shell and header type, baffle type, tube type
and layout will use program defaults.
The Shell&Tube design logic will optimise the heat transfer against the
allowable pressure drop on both the shell and tube sides. The program has
built in heuristic rules, which will stop it searching once it realizes that further
calculations are pointless.
Help may be obtained at any time by placing the cursor on an item and
pressing F1

Next step:
Process Overview
 Process Overview
The details of the process data and some basic geometry are shown in the
table below:

Cold Side Hot Side

Fluid Units
Boiler Feedwater Fuel Oil

Total Flowrate 59100 284000 kg/h

Temperature (In/Out) 50 / 165.3 213 / 168 °C

Density (In/Out) 879.4 / 909.8 kg/m³

Specific Heat (In/Out) 2.34 / 2.18 kJ/kg*K

Viscosity (In/Out) 1.94 / 3.37 mPa*s

Thermal C onductivity (In/Out) 0.1 / 0.107 W/m*K

Inlet Pressure 50 12 bar (abs)

Allowable Pressure Drop 1 1.5 bar

Fouling Resistance (min) 0.000088 0.0005 m2 °K/W

Note: Exchanger to be Horizontal

Next step:
Building the Simulation
 Building the Simulation
Launch Aspen Exchanger Design & Rating (EDR) from either the shortcut or
the AspenOneTool bar. Select Shell & Tube Exchanger (Shell&Tube) from the
New tab and click OK.

Shell&Tube will open where the screen as shown below will be displayed.
To change the units which data can be entered into the program there are a
number of options;
Click on the drop down arrow by US and select SI units
From the menu bar, select Tools, then Program Settings. From the General
tab set SI as the Default set of the units of measure. Click OK, where the next
time Shell&Tube is started, SI units will be the default set of unit.
Highlight the Application Options from the tree menu structure on the left-
hand side and then ether the data as follows;
Set the calculation mode to Design
Location of hot fluid to Tube side
Press the Next button to navigate to the next form where input data is
required or highlight Process Data from the navigation tree. Enter the process
data from the process overview table previously given.
The flowrate data has been specified as kg/h whereas the input screen by
default shows kg/s. Therefore click on the scroll down arrow by the mass
flowrate units and select kg/h then enter the data.
When sufficient data has been entered necessary for the program to run, the
red cross will disappear from the menu tree.
(NOTE: Numbers in red are program defaults and are not entered by the
user)
Enter the physical properties for the hot side fluid, where as property data is
supplied at two temperature points. User Specified Properties is selected for
the property package.
Enter the property data for the two temperature points.
By default, two pressure levels are available, where in this example data at
only one pressure level is to be entered. To delete the second pressure level
you have two options:
Enter 1 for the number of pressure levels
Highlight the second pressure level in the Pressures column then click on the
Delete Set button.
(NOTE: The Overwrite properties box is checked for direct input of properties)
Use one of the physical property packages to retrieve the cold stream
properties.
Either B-JAC Databank or COMThermo can be selected. Initially the B-JAC
databank will be described below, but in the Continuation Exercise 2 the
COMThermo method is used.
Select B-JAC databank as the Physical property package and then click on the
Search Databank button.
Type in the first few letters of the fluid required, then highlight from the list
and click on the Add button to enter in the selected components list. Click on
OK.
Select the Cold Side Properties tab and click on the Get Properties button
where the program will calculate the properties of water at the default
pressure and temperature range.
Save your case – All the required data have been entered. It is important to
save the dataset. This is achieved from the menu by File, then Save As. Now
you can run by clicking on the Run button or from the menu, Run, then Run
TASC.

Next step:
Viewing the results
 Viewing the Results

Now the example has been run the Results screens can now be viewed

Next step:
Properties from COMThermo
 Properties from COMThermo

The above example used B-JAC database to determine the physical properties
for the cold stream. COMThermo can be used instead, where the method is
described below.
Reload the Design case and re-run.
Select COMThermo as the Physical property package for the Cold side
composition. Click on the Search Databank button.
Type in the first few letters of the fluid required, then highlight from the list
and click on the Add button to enter in the selected components list. Click on
OK.

Enter a composition fraction of 1 for water and then from the Property
Methods tab select Ideal-Ideal as the property package
Select the Cold Side Properties tab and click on the Get Properties button
where the program will calculate the properties of water at the default
pressure and temperature range.
Run Shell&Tube and compare the areas with the Design generated with B-JAC
Database.

Next step:
Creating a Checking Case
 Creating a Checking Case
The Design mode of Shell&Tube will provide a number of designs that will
achieve the required duty. These can be viewed on the ‘Results | Results
Summary | Optimization Path’ tab. Here there will be a list of the different
geometries evaluated by Shell&Tube indicating if they meet the duty and
pressure drop requirements and also if they are a "near" miss. At the top of
this table is the ‘Current selected case’ number that meets both the duty and
pressure drops and has the lowest cost value.
In order to fine tune and fully optimize the design the Rating/Checking mode
in Shell&Tube should be used.
Select ‘Run’ from the main menu and then ‘Update file with Geometry –
Shell&Tube’. This will take the optimized heat exchanger geometry and create
a Rating/Checking case.
The detailed geometry of the exchanger can now be changed if necessary
from the Exchanger Geometry screens.

Return to:
Overview
 Shell and Tube Heat Exchanger Overview
A shell and tube exchanger has a bundle of tubes within a shell. One stream
flows through the tubes, the other in the shell, over the tubes. Many variants
of this basic configuration exist. Further information on the various
components of an exchanger, and on the reasons for selecting particular sizes
or configurations, is available on the following key topics:

Shell and Head Types

TEMA Shell Types
Head Types
Shell/Head Combinations
Double Pipe and Multi-tube Exchangers

Shell Diameters
Pass Arrangements
Single Pass Exchangers
Allocation of Streams

Nozzles - Sizing
Nozzles - TEMA Standards
Nozzles - Achieving TEMA Standards

Tube Bundles

Tube Diameters
Tube Wall Thicknesses
Common Tube Diameters and Thicknesses
Standard Bare Tube Diameters and Gauges

Tube Pattern and Tube Pitch

Tube Length - Maximum Value
Tube Length / Number of Passes
Tube Counts

Baffle Types
Single Segmental Baffles
Double Segmental Baffles
Triple Segmental Baffles
Orifice Baffles
Disc and Doughnut Baffles
Rod Baffles
Baffle Cut Orientation
Baffle Spacing and Cut

Maximum Unsupported Tube Span Length

Sealing Strips

Expansion Joints

Quick Guide to Geometry Selection

TEMA

See also:
Shell&Tube Input
Shell&Tube Exchanger Geometry
Shell&Tube Results
 Shell&Tube Shell and Head Types
Shells and front and rear end heads for a shell and tube exchanger come in a
range of types identified by a letter, designated by TEMA
There are also some shell and tube type exchangers, such as double pipe and
multi-tube, which are not covered by TEMA

See also:
TEMA Shell Types
 Shell&Tube Shell Diameters
Heat exchanger shells are normally manufactured from standard pipe for
diameters up to 610 mm (24 inch) outside diameter, and from rolled plate
thereafter. In theory, then, very large shell diameters are possible. In
practice, however, most exchanger manufacturers cannot handle or drill
tubesheets greater than approximately 3 meters (120 inches) in diameter and
engineers contemplating shell sizes of this order should always refer to
prospective manufacturers for advice. At the other end of the scale heat
exchangers as small as 51 mm (2 inches) diameter with 6.35 mm (1/4 inch)
tubes have been manufactured. For exchangers with 19.05 mm (3/4 inch)
tubes, 152 or 203 mm (6 or 8 inches) is usually the minimum size shell used.
The size of pipe shells is clearly determined by the nominal size of available
pipe - normally 152, 203, 254, 305, 356, 406, 457, 508 and 610 mm nominal
bore (6, 8, 10, 12, 14, 16, 18, 20 and 24 inch). It is, of course, the shell
inside diameter (ID) that is of most interest to the thermal design engineer.
For standard wall pipe the IDs corresponding to the above nominal sizes are,
respectively, 154, 203, 255, 305, 337, 387, 438, 489 and 591 mm (6.07,
7.98, 10.02, 12.00, 13.25, 15.25, 17.25, 19.25 and 23.25 inches).
For plate shells any diameter is possible but, in practice, design engineers
tend to work in increments of 50 mm (e.g. 650, 700, 750 mm ID) or 2 inches
(e.g. 26, 28, 30 inches ID).

See also:
Pass Arrangements
 Shell&Tube Nozzles - Sizing
Generally speaking, heat exchanger design engineers will try to keep nozzle
sizes as small as possible to keep down costs. Wherever possible, this means
that making the nozzle the same diameter as the connecting pipework. It
should be remembered, however, that any pressure loss in the nozzle can
often be more effectively used in the shell or the tubes and engineers should
always check each run to ensure that *P is not being 'wasted' in a nozzle
when, for instance, it could be used to decrease the baffle pitch, or increase
the number of tube-passes.
If possible, nozzles which are very large compared to the shell (greater than
one-third shell diameter) should be avoided since these will require extensive
re-enforcing and costly additional non-destructive examination of the shell.
Where pressure drop is not a problem the minimum nozzle size is usually
limited by the maximum allowable fluid velocity. This is a metallurgical
problem since excessive velocities can lead to erosion, especially if the fluid
contains solids in suspension. Clearly, the velocities which can be tolerated
will be much higher for gases than for liquids and it is more helpful to talk in
terms of energy, or density times velocity squared (* v2) rather than velocity.
On this basis a safe upper limit for most fluids is around 9000 kg/ms2 (6000
lb/ft s2) and tube side nozzles should be sized such that this value is not
exceeded.

See also:
Nozzles - TEMA Standards
 Shell&Tube Tube Bundles
Ideally a tube bundle will occupy as much of the inside of the shell as
possible, but in practice tubes will be missing in a number of places.
1. Near the shell wall, particularly if there is a pull through floating head.
2. Next to the inlet nozzle, to give increased flow area (reduced velocity), or
to give space for an impingement plate under the nozzle.
3. In pass-partition lanes, corresponding to the position of the pass partition
plates between passes, in the front end or rear end heads.
In some positions tubes may be replaced by the tie rods that hold the baffles
together.
The distance from the shell to the first tube row and to the last tube row
define the size of the region adjacent to the nozzle where tubes are not
present.
Where tubes are missing, there can be flow paths whereby the fluid could
bypass the bundle, with adverse effects on the heat transfer. This can be
particularly significant when the baffle cut is in line with the nozzle, so tubes
removed under the nozzle give a large bypass area. Bypass flows are reduced
by the use of sealing strips, between the bundle and the shell, and in any
pass partition lanes which are in-line with the main cross-flow direction.
For segmentally baffled exchangers, the bundle can be divided into two
regions, the baffle overlap region, where there is predominantly crossflow
through the bundle, and the window flow region, where the flow changes
direction between one baffle space and the next.
A normal bundle is one with tubes removed next to nozzles. A full bundle is
one with no such tubes removed. In some exchangers, a reduced baffle cut is
used, but there are No Tubes in the Window (NTIW). Such designs have the
advantage that all tubes are supported by every baffle, so the maximum
unsupported tube length is reduced, and with it the risk of vibration damage.

See also:
Tube Diameters
 Shell&Tube Tube Diameters
TEMA section 'C lists nine standard tube outside diameters ranging from 6.35
to 50.8 mm (1/4 to 2 inch). Generally speaking tubes less than 12.7 mm (1/2
inch) are only used for small 'proprietary' type exchangers and tubes greater
than 25.4 mm (1 inch) would only be required for severely pressure drop
limited designs. The standard diameters in general use are, therefore, 12.7,
15.88, 19.05 and 25.4 mm (1/2, 5/8, 3/4 and 1 inch).
The choice of diameter is usually based on established practice rather than
the technical merits of any particular case. Thus 12.7 and 15.88 mm tend to
be specified in smaller exchangers for general industrial use while, in the
Process Industries it is established practice to use 19.05 mm tubes as
standard with 25.4 mm being occasionally used for vertical thermosiphon
reboilers and other services where tube side pressure drop presents a
problem.
There are several reasons why 19.05 mm tubes are by far the most
commonly used in the Process Industries:
19.05 mm is the smallest diameter recommended by section 'R' (the section
applicable to petroleum refineries) of the TEMA code
Tubes smaller than 19.05 mm OD tend to have inside diameters which make
mechanical cleaning difficult
Tube end welding of the smaller tubes is more difficult
The constraint imposed by the initial selection of a standard tube OD leads to
a reduction in the man hours required for design and cost estimation.

See also:
Tube Wall Thicknesses
 Shell&Tube Tube Pattern and Tube Pitch
Tubes may range in diameter from 12.7 mm (0.5 in) to 50.8 mm (2 in) but
19.05 mm (0.75 in) and 25.4 mm (1 in) are the more common sizes. The
tubes are laid out in triangular or square patterns in the tube sheets.

There are four common patterns (sometimes called layouts).

Triangular: 30 degrees
Triangular: 60 degrees
Square: 45 degrees
Square: 90 degrees

The 90 degree pattern has tube rows ‘in-line’. The other layouts are
‘staggered’.
The square layouts permit access to tubes within the bundle for cleaning.
Triangular layouts (with conventional tube pitches) do not. With multiple
passes, access to all the tubes within the bundle may only be possible if the
layouts within the various passes are aligned.
90 degree layouts are common in boiling applications such as kettles and
flooded evaporators
30 degree layouts are more common than 60 degrees. The angles are usually
defined relative to the flow direction, but are sometimes referred to the
vertical. Clarification may be needed in exchangers with a vertical baffle cut,
where the flow is side to side.
The triangular arrangement allows more tubes in a given space. The tube
pitch is the shortest centre-to-centre distance between tubes. The tube
spacing is given by the tube pitch minus the tube diameter. The tube
pitch/tube diameter ratio is normally 1.25 or 1.33. Since a square layout is
used for cleaning purposes a minimum gap of 6.35 mm (0.25in) is allowed
between tubes.
For assembly reasons a gap must exist between the outer tubes forming the
bundle and the inside surface of the shell (bundle to shell clearance). This gap
depends upon the type of heat exchanger (fixed tube sheet, U-tube or floating
head). A larger gap is usually needed adjacent to the shell nozzles to avoid
excessive pressure drop (nozzle clearance). Tubes are either removed from
the bundle opposite the nozzles or a greater shell diameter is used at the
nozzles, the latter is known as a vapor belt.
A larger tube-to-tube spacing is needed between tubes in adjacent passes,
when there is more than one pass. This is ‘pass partition gap’ is to allow for
pass partition plates which are required to separate flows in the channels

See also:
Tube Length - Maximum Value
 Shell&Tube Tube Counts
The tube count is the total number of tubes in an exchanger. For this
purpose, a U-tube is counted as two-tubes, so the tube count still gives the
total number of holes in the tubesheet.
Since tubes are laid out in a regular array, calculating the approximate
number of tubes in an exchanger is relatively straightforward. Allowance can
be made for tubes removed adjacent to nozzles, pass partition lanes, etc. An
exact tube count, however, can only be done when the position of every tube
in the exchanger is fixed, and allowance has to be made for tubes removed to
give space for tie-rods.
Shell&Tube uses an exact tube count in all calculation modes.
The Tube Layout diagram in Shell&Tube shows you an exact tube count, and
you can modify this to correspond exactly to an exchanger you are modeling.
You can do this by making sure that all the Bundle Layout input items are set
correctly. The Pass Details option lets you specify the number of rows and
column of tubes in each tube pass. If the Tube Layout generated needs
further modification, you can select to use the existing layout, first making
additional revisions by editing the diagram, by adding or deleting tubes, or
moving tube-pass regions.
You also have the option to explicitly specify a tube count in the input, and
this value will be used in the heat transfer and pressure drop calculations. If
your specified value differs from the calculated value you will get a warning.
As long as the Tube Layout calculated by Shell&Tube more or less matches
your exchanger, using such a specified tube count should be a very good
approximation and will save you the trouble of detailed editing of the
diagram.

See also:
Baffle Types
Number of Tubes (total)
Tubes in Layout
Tube Layout option
 Shell&Tube Baffle Types
Baffles are installed on the shell side for two reasons. Firstly they cause
crossflow over the tube bundle, and hence higher velocities and higher heat-
transfer rates due to increased turbulence. Secondly they support the tubes
thus reducing the chance of damage due to vibration. There are a number of
different baffle types which give this turbulence due to crossflow:
Single Segmental Baffles
Double Segmental Baffles
Triple Segmental Baffles
Disc and Doughnut Baffles

The centre-to-centre distance between baffles is called the baffle-pitch or

baffle spacing and this can be adjusted to vary the crossflow velocity. In
practice the baffle spacing is not normally greater than a distance equal to the
inside diameter of the shell or closer than a distance equal to one-fifth the
diameter or 50.8 mm (2 in) whichever is greater. In order to allow the fluid to
flow backwards and forwards across the tubes part of the baffle is cut away.
The height of this part is referred to as the baffle-cut and is measured as a
percentage of the shell diameter, e.g. 25 per cent baffle-cut. The size of the
baffle-cut (or baffle window) needs to be considered along with the baffle
spacing. It is normal to size the baffle-cut and baffle spacing to equalize the
velocities through the window an in crossflow respectively.

There are two main types of baffle which give longitudinal flow:
Orifice Baffles
Rod Baffles

In these types of baffle the turbulence is generated as the flow crosses the
baffle.
 Shell&Tube Quick Guide to Geometry Selection
The following is a quick guide on how exchanger geometry is selected
Tube outside diameter - for the process industry 19.05mm (3/4") tends to
be the most common.
Tube wall thickness - there is not short cut for deciding this. Reference
must be made to a recognized pressure vessel code.
Tube length - for a given surface are the longer the tube length the cheaper
the exchanger although a long thin exchanger may not be feasible.
Tube Pattern (layout) - 45 or 90 degree patterns are chosen if mechanical
cleaning is required otherwise a 30 degree pattern is often selected because it
provides a higher heat transfer and hence smaller exchanger.
Tube pitch - the smallest allowable pitch of 1.25 times the tube outside
diameter id normally used unless there is a requirement to use a larger pitch
due to mechanical cleaning or tube end welding.
Number of tube passes - is usually one or an even number (not normally
greater than 16). Increasing the number of passes increases the heat transfer
coefficient but care must be taken to ensure that the tube side rho-v2 is not
greater than about 10 000 kg/m s2
Shell diameter - standard pipe is normally used for diameters up to 610mm
(24"). Above this they are made from rolled plate. Typically shell diameters
range from 152 mm to 3000 mm (6" to 120").
Baffle type - single segmental are used by default with other types being
considered if pressure drop constraints or vibration is a problem.
Baffle spacing - this is decided after trying to balance the desire for
increased crossflow velocity and tube support (smaller baffle pitch) and
pressure drop constraints (larger baffle pitch). TEMA provides guidance on the
maximum baffle pitch and the absolute minimum baffle pitch is about 50 mm
(2").
Baffle cut - this depends on the baffle type but is typically 45% for single
segmental baffles and 25% for double segmental baffles.
Nozzles and impingement protection - for tube side nozzles, the rho-v2
should not be greater than about 9000 in kg/m s2. For shell side nozzles, the
maximum rho-v2 should not exceed 2230 kg/m s2 for non-corrosive, non-
abrasive single phase fluids and 740 kg/m s2 for other fluids. Impingement
protection is always required for gases which are corrosive or abrasive,
saturated vapors and two phase mixtures. Shell or bundle entrance or exit
areas should be designed such that a rho-v2 of 5950 kg/m s2 is not exceeded.
 Shell&Tube TEMA
TEMA is the U.S. Tubular Exchanger Manufacturers' Association, which
produces a regularly updated set of standards, relating (primarily) to
mechanical design considerations for shell and tube heat exchangers.
 Shell and Tube Geometry Overview
This appendix details the geometry of shell and tube heat exchangers.
Bundle Geometry
Plugged Tubes
Transverse Baffles - Baffle Cut
 Shell and Tube Geometry Bundle Geometry
There are many components that together form the tube bundle of a shell and
tube heat exchanger. The following inputs determine the relative location of
these components.
Tube Length
Number of Baffles
Baffle Spacing Center-Center
End Length at Front Head (tube end to closest baffle)
End Length at Rear Head (tube end to closest baffle)
Baffle Spacing at Inlet (Shell Side Inlet Nozzle)
Baffle Spacing at Outlet (Shell Side Outlet Nozzle)
Length of Tube beyond Support/Blanking Baffle

The following section illustrates how the components within a tube bundle are
defined within the different types of shell and tube heat exchangers.
U-Tube
Fixed Tubesheet
Floating Head

Note the following special cases:

`F' Shell Type
`G' Shell Type
`H' Shell Type
`I' Shell Type
`J' Shell Type

Back to:
Shell and Tube Geometry - Overview
 Shell and Tube Geometry Transverse Baffles -
Baffle Cut
The baffle cut(s) depend on the baffle type:
Single Segmental Baffles
Double Segmental Baffles
Triple Segmental Baffles
 Tube Layout: Overview
This appendix contains the following topics:
Tube Layout: How it is Calculated
Tube Layout: How to get what you want
Tube Layout: Editing
Tube Layout: Other Facilities

Tube Layout: New Tube Layout Calculations

Tube Layout: Changes to Bundle Layout Defaults
 Tube Layout: How it is Calculated
There are three steps in determining the tube layout:
Determining the outer limits of the bundle – and the overall number of tube
1
rows and columns
Determining the number of rows and columns in each pass region, and
2
hence the location of pass partition lanes
3 Determining the location of each tube in each pass region.

The “outer limits of the bundle” mean not only the outer radial limit
determined by the shell-bundle clearance, but also the limits at the top,
bottom, and two sides. Initial estimates of the limits come from the space
required under shell side inlet and outlet nozzles, but exact values, consistent
with an integral number of tube rows and columns, are determined by the
tube pattern and pitch, and by the width of pass partition lanes, if any. Pass
partition lane widths need to be larger if they must allow for U-bends,
longitudinal baffles, or cleaning lanes (in 45 degree patterns).
For staggered tube patterns, the bundle outer limits can also be affected by
the input for tube layout symmetry. This can adjust the number of tube rows
and or columns, if necessary, to give tubes along the vertical and/or
horizontal tube diameters.
Given the bundle outer limits, and hence the total number of rows and
columns, the number of rows and columns in each pass region is set to
equalize, as near as possible, the number of tubes in each pass region. This is
done automatically by the program. With the Specify Pass Details layout
option, however, you can explicitly specify the number of rows and columns in
each pass region – and thus set deliberately unequal numbers of tubes if you
wish.
Staggered layouts have tubes in alternate locations (meaning every other
location) on the underlying grid of rows and columns. When possible, this is
selected to optimize the number of tubes in each pass region. When the
locations in adjacent pass regions are interdependent, for example with U-
tubes or cleaning lanes, the overall bundle count is optimized.
See also:
Tube Layout Option
Tube Layout: How to get what you want
 Tube Layout: How to get what you want
Shell&Tube provides a range of inputs to let you get the tube layout you
want. It will provide defaults for all the inputs, but if the layout generated
with defaults does not meet your requirements, then you can modify the
various inputs as required.
Inputs affecting the tube layout include the following
· Number of passes
· Pass Layout: Single banded, H-banded, or Double banded (quadrant)
· Pass Layout orientation: Standard (horizontal) or Vertical – determines
primary PP lane orientation
· Tube Pitch and Tube Pattern – determine spacing of tube rows and
columns
· Pass partition (PP) lane widths – horizontal and/or vertical
· U-bend orientation – horizontal or vertical
· U-bend minimum diameter – affects PP lane width
· Cleaning lane or tube alignment – affects PP lane widths
· Remove tubes below nozzle – none, normal, in nozzle projection (for
each nozzle)
· Tube Layout Design – Full or normal bundle – determines default for
tubes removed under nozzles
· Shell bundle clearance / Outer tube limit diameter : one or the other
· Open distances on top / bottom / left / right of bundle: If specified
exactly, these will override specification of tube removed under nozzles.
· Tube Layout Symmetry – Standard, Full, or not enforced – sets odd or
even number of rows or columns, to adjust open distances at sides, and
ensure a central row/column of tubes when appropriate.
· Replace tubes by Tie rods (if necessary): can make small changes to
number of tubes.
The above apply to the New Layout option in performance modes. They are
mostly also available in Design mode, exceptions being number of passes and
explicit specification of clearances and open distances, which depend on
exchanger size.
When using Specify Pass Details, the above inputs for clearances, open
distances, and PP lane widths are used directly. Other items above are used to
set default values for these inputs.
You do not have to get a layout exactly right before doing calculations on an
exchanger. You can explicitly specify the number of tubes to be used in the
thermal and hydraulic calculations. Differences in detail between your
exchanger and the layout the program generates often have only a small
effect on calculated performance. Whenever the layout predicts a different
number of tubes from what you specify, a warning is produced.
See also:
Tube Bundle Layout: How it is Calculated
Bundle Layout
 Tube Layout: New Tube Layout Calculations
The revised tube layout calculations in V7.2 lead to important new features:
· New Pass Details input shows default values of key geometric features
of each tube pass, such as the number of tube lines and columns in each. You
can replace default values with input, letting you exactly represent the layout
in an existing exchanger.
· Thermal performance calculations make explicit allowances for different
numbers of tube in each pass.
· You can explore the effect of deliberately making the number of tubes
per pass non-uniform. In the Pass Details input, when you adjust the size of
one pass by specifying the number of tube rows or columns, the size of all
other passes adjusts accordingly.
· Tubecount from the layout is displayed as an input parameter when you
use the Pass Details input. This means you can easily explore the effect on
tubecount of changing layout inputs such as bundle limits or U-bend
orientation, without needing to run the program.
· The new tube layout calculation has improved optimization procedures
for determining the split of tubes among the various passes, and for staggered
layouts, selecting the best of the two possible grid occupancies.
Previous facilities, such as using interactive graphics to modify a calculated
tube layout, remain in place. The new option Specify Pass Details should
mean that, for the majority of exchangers, editing to modify tube locations is
not necessary.
Specify Pass Details is found under Tube Layout option, on the Bundle
Layout tab.
See also:
Bundle Layout
Changes to Bundle Layout Defaults
 Tube Layout: Changes to Bundle Layout
Defaults
For V7.2, the some changes have been made to defaults of inputs related to
the bundle layout to give a better representation of engineering practice.
These include:
· Orientation of U-bends: The default no longer depends on baffle cut
orientation. The default is vertical for two-pass cases and horizontal for more
than two passes.
· Pass Layout orientation: The horizontal orientation, the standard case,
is now the usual default. Except for a few special cases, there is no
dependence on baffle cut. The standard (horizontal) orientation means that
whenever there are multiple parallel pass partition lanes, they are horizontal.
· Tube Layout Symmetry: A new calculation procedure for tube layouts
means that changes have been made in the way this flag is used. It applies
only staggered tube patterns and determines the level of symmetry that is
required of the bundle layout, relating in particular to whether there is a
central row and or column of tubes. It might affect the bundle outer limits.
All of these default changes can affect the calculated bundle layout, and
hence the number of tubes in the bundle. Even if none of the values are
defaulted, the new bundle calculation procedure itself, with improved
optimization, can also change the calculated number of tubes. Both increases
and decreases in number of tubes in the layout can occur, but changes will
rarely be large.
If you have explicitly specified the number of tubes, giving a value to be used
in preference to the tube layout value, changes in thermal performance will
normally be minimal.
See also:
Bundle Layout
 Shell&TubeMech: Headings/Application sheet
Use this sheet to specify Headings, which appear at the top of the TEMA
specification sheet, Input Summary results, and the Title block of the
drawings. Headings are 1 to 5 lines of up to 75 characters per line. Note that
only the first 40 characters of each line appear on the drawings.
To create global headings for use by any Aspen EDR program, click Tools |
Program Settings, display the Headings/Drawings tab, and enter the
heading information.
For the application, select either a complete exchanger design of a shell-and-
tube heat exchanger or a pressure vessel.
 Shell&TubeMech: Codes and Standards Sheet
Use this sheet to specify:
Design code
The Shell&TubeMech program selects applicable mechanical design methods
based on the selected code: ASME (American), CODAP (French), AD-
Merkblatter (German), EN 13445 (European)
Material standard
The selected material standard - ASME, AFNOR, DIN, JIS or EN - determines
the materials of construction to be used. The default is the material standard
per applicable code specified.
TEMA class
Select the appropriate TEMA class for the service:
Class B - chemical service exchanger (default)
Class C - general service exchanger
Class R - refinery service exchanger
Code only - Program will not use TEMA defaults for corrosion allowances,
minimum thicknesses, etc.
Dimensional standard
The selected dimensional standards - ANSI (American), ISO (International),
or DIN (German) - apply to such things as pipe cylinder dimensions, nozzle
flange ratings, and bolt sizes. DIN also encompasses other construction
standards such as standard tube pitches.
Service class
If you select low temperature (design temperature less than -50°F) or
lethal service (exchanger contains a lethal substance), the program selects
the corresponding Code requirements for that class, such as full radiography
for butt welds and PWHT for carbon steel construction. The default is normal
service class.
 Shell&TubeMech: Design Specifications Sheet
Use this sheet to specify:
Design pressure
Design pressure should be set higher than the highest normal operating
pressure. If static pressure is to be considered, add the static to the normal
design pressure. For components subject to two pressures, the program
follows standard methods to investigate the effect of simultaneous design
pressures (for example, TEMA).

Vacuum design pressure

The program will design simultaneously for internal as well as external
pressure. The program expects an entry of 15 psia (1 bar) for full vacuum
condition.

Test pressure
The program will calculate the required hydrotest pressure in accordance with
the specified design code.

Design temperature
This is the design temperature at which material properties will be obtained.

Corrosion allowances
Corrosion Allowance is obtained from the TEMA standards as follows: For
carbon steel TEMA B and C: 0.0625" (1.6 mm). For carbon steel TEMA R:
0.125" (3.2 mm). Enter zero for no corrosion allowance. There is no default
corrosion allowance for materials other than carbon steel. You can specify any
reasonable value for corrosion allowance.

Radiographing
The program follows the applicable construction code in the calculation of
weld joint efficiencies based on the degree of radiography performed on the
subject welds. Typically the joint efficiencies used in the thickness formulas
follow these values:
Degree of
None Spot Full
Radiography:

Joint Efficiency: 0.7 0.85 1

Non-destructive testing performed on welds (i.e. radiography) can directly
affect the joint efficiency used in the thickness calculations. Generally, the
higher the efficiency, the thinner the component.

Radiographing (RT-2 or RT-3)

Post weld heat treatment

The post weld heat treatment requirement is dependent upon the applicable
Code requirements. If specified the cost estimate will be adjusted to include
the cost of post weld heat treatment of the unit.

Lethal service
If the fluids in the exchanger are considered to be of lethal nature, specify
lethal service. The default is no.

Service Type
· Unfired Steam Boilers uses rules per ASME UG-16(b)(3).
· Air, steam, water service uses rules per ASME UG-16(b)(4).
UG-16(b) is applied to all components.
The default is no special service type.

Plate tolerance
You can specify a tolerance to plate materials. Tolerance will be added to the
required code thickness calculated. The program default is zero tolerance.

Add static head

With this option, the program calculates the weight of the fluid in either the
shell or tube sides. The program uses fluid densities that are available from
the thermal program or that are manually entered. Otherwise, it uses the
density of water. The weight is added as an equivalent pressure to the design
pressure.
The default is no static head.

Static pressure (overrides program)

If the option to add the static head to the design pressure is used, the
program calculated equivalent pressure value can be overridden with a user-
specified value.
The default is no static head.

Differential Design Pressure

If the differential design pressure option is used, the program calculated value
can be overridden with a user-specified value.
The default is no differential design pressure.

Use Differential Design Pressure

With this option, the program uses UHX and TEMA (if TEMA is selected
elsewhere) differential pressure design rules for the tubesheet design. The
program will also design other components subject to both shell side and tube
side pressures, such as tubes and floating heads, to differential pressure
design.
Note: Using this option assumes that the equipment owner has failsafe
mechanisms to insure that the common components never experience the full
non-differential design pressure.
 Shell&TubeMech: Heat Transfer Data and
Operating Loads
The Heat Transfer Data and Operating Loads screen contains the following
inputs:
Film Heat Transfer Coefficient
Inlet Temperature
Outlet Temperature
Inlet Pressure
Outlet Pressure
Mean Metal Temperature
Highest Tube Wall Temperature
Lowest Tube Wall Temperature
Ambient Temperature
ASME for Thermal Cases - use Operating Loads
Operating Loads Table
1St Column Loads
Shell Side and Tube Side Operating Pressures and Temperatures
 Shell&TubeMech: Front Head Sheet
Use this sheet to specify:
Front head type
This is the TEMA type front head closure.
Front head cover type
If you selected front head type B, you must select a cover type.
Front head connected to a cylinder
A cylinder is required if a nozzle has been indicated at Zone 2 on the
Nozzlessheet of the Nozzles - General input form. The default is the front
head cylinder provided for all types.
Front channel/cover bolted to tubesheet
Select Yes to have the channel assembly bolted to the tubesheet. Select No
to have the head welded to the tubesheet with no flanges. The default is the
channel bolted to the tubesheet for A and B type front heads.
 Shell&TubeMech: Front Head Type
Specify the TEMA type front head closure. The default is B - bonnet bolted of
integral with tubesheet.

The high pressure D type is a shear key ring. The Shell&TubeMech program
uses one specific design approach for this type.
See Also
Front Head Sheet
 Shell&TubeMech: D Type Front Head Design
The Aspen Shell&TubeMech program uses one specific design approach for the
D type, high pressure closure. The pressure vessel design methods used in
the program are not specifically defined in the design codes, ASME or TEMA.
Therefore, it is recommended that you carefully review the Shell&TubeMech
results for the high pressure closure and modify as necessary to meet your
specific design construction needs.
These are the construction details for the Shell&TubeMech D type head:

See Also
Front Head Type
 Shell&TubeMech: Front Head Cover Type
Select the cover type for the B type front head. The default is ellipsoidal cover
(Korbbogen for ADM).

See Also
Front Head Sheet
 Shell&TubeMech: Front Head Cylinder Details
Sheet
Use this sheet to specify these front head cylinder details:
Outside and inside diameters
Thickness
Length
Length for external pressure
Joint efficiency
Girth weld location
Longitudinal weld location angle
If you specify an outside diameter, the program will hold the outside
diameter and calculate and inside diameter based upon the calculated
required cylinder thickness. If you specify an inside diameter, the program
will hold the inside diameter and calculate and an outside diameter based
upon the calculated required cylinder thickness.
If a pipe material is specified, cylinders 24 inches and smaller, we recommend
that you specify the outside diameter so that a standard pipe wall thickness
can be determined.
If check rating an existing design, specify the cylinder outside diameter or
inside diameter, thickness, length, length for external pressure, and joint
efficiency.
 Shell&TubeMech: Cover Details Sheet
Use this sheet to specify these front head cover details:
Outside and inside diameters
Thickness
Forming tolerance
Joint efficiency
Head ratio
Straight flange length
Depth
If check rating an existing design, specify the cover outside diameter, cover
inside diameter, cover thickness, and cover joint efficiency.
 Shell&TubeMech: Front Head Flat Heads Sheet
If you select a font head type that includes flat heads, use this sheet to
specify the relevant details.
Front head flat bolted cover
If check rating an existing design, specify the following flat bolted, front
head cover information:
Clad thickness
Clad OD (if cladded)
1st recess depth (from center)
1st recess diameter
2nd recess depth (from center)
2nd recess diameter
Front head flat welded cover
If check rating an existing design, specify the following flat welded, front head
cover information:
Clad thickness (if cladded)
Flat head weld attachment type
“C” factor in calculation of flat cover
 Shell&TubeMech: Shell Sheet
Use this sheet to specify:
Shell type
This is the shell TEMA type, except type V.
Exchanger (vessel) position
Specify horizontal (default) or vertical position.
Shell outside and inside diameters
If you specify an outside diameter, the program will hold the outside
diameter and calculate and inside diameter based upon the calculated
required cylinder thickness. If you specify and inside diameter, the program
will hold the inside diameter and calculate and an outside diameter based
upon the calculated required cylinder thickness.
If a pipe material is specified, shells 24 inches and smaller, we recommend
that you specify the outside diameter so that a standard pipe wall thickness
can be determined.
 Shell&TubeMech: Shell Type
These are the shell type choices:

The V type shell, which is not currently part of the TEMA standards, is used
for very low shell side pressure drops. It is especially well suited for vacuum
condensers and has an advantage over the X shell, in that it can readily have
vents at the top of the bundle.
The vapor belt is an enlarged shell over part of the bundle length. It is
essentially a cross flow exchanger in this section. The remaining portions of
the bundle on each side are then baffled and fitted with vents and drains.
Default: E type (except pool boilers), K type for pool boilers
 Shell&TubeMech: Shell Cylinder Sheet
If check rating an existing design, use this sheet to specify these shell
cylinder details:
Cylinder thickness
Cylinder length
Length for external pressure
Cylinder joint efficiency
Girth weld location
Longitudinal weld location angle
Note: girth and longitudinal weld locations are not considered in the code
calculations.
If external pressure is controlling the shell cylinder design, you can specify
shell stiffening rings to reinforce the shell. If details are not provided, the
program will select a ring size.
 Shell&TubeMech: Kettle Cylinder Sheet
If the exchanger has a kettle type shell, use this sheet to specify the kettle
cylinder outside or inside diameter.
If you are check rating an existing design, use this sheet to specify these
details:
Kettle length
Kettle length for external pressure
Kettle joint efficiency
 Shell&TubeMech: Kettle Reducer/Weir Sheet
If the exchanger has a kettle type shell and you are check rating an existing
design, use this sheet to specify these kettle reducer details:
Reducer thickness
Reducer cover joint efficiency
Reducer conical angle
When liquid recirculation is required in a kettle reboiler service, a weir plate
is generally specified beyond the U-bends. Use this sheet to specify the
following Weir related details:
Weir in kettle option
Weir plate material
Weir thickness
Weir plate outer diameter
Weir height
Shell&TubeMech will add additional required shell length for the weir plate
and reservoir.
 Shell&TubeMech: Vapor Belt Sheet
Use this sheet to specify the details for the vapor belt assembly.
The vapor belt acts as a distribution device for the flow into the bundle. The
vapor belt may act also as a flange & flued type expansion joint device.
 Shell&TubeMech: Rear Head Sheet
Use this sheet to specify:
Rear head type
The rear head type selection should be based on service requirements.
Rear head cover type
Select the cover type for the rear head.
Rear head connected to a cylinder
A cylinder is required if a nozzle has been indicated at Zone 8 on the
Nozzlessheet of the Nozzles - General input form. The default is the rear head
cylinder provided for one-pass exchangers.
Rear channel/cover bolted to tubesheet
Select Yes to have the channel assembly bolted to the tubesheet. Select No
to have the head welded to the tubesheet. The default is the channel bolted
to the tubesheet for L and M type rear heads.
 Shell&TubeMech: Rear Head Type
The rear head type selection should be based upon service requirements.

The removable tube bundle types - P, S, T, U, and W - provide access to the

bundle for cleaning and do not require an expansion joint.
The fixed tubesheet types - L, M, and N - do no allow access to the bundle but
have lower construction costs.
The default is U type for kettle shells; M type for all others.
See Also
Rear Head Sheet
 Shell&TubeMech: Rear Head Cover Type
Select the cover type for the rear head.

The default is flat bolted for L, N, P, and W types; ellipsoidal for M type;
dished for S and T types
See Also
Rear Head Sheet
 Shell&TubeMech: Rear Head Cylinder Details
Sheet
Use this sheet to specify these rear head cylinder details:
Outside and inside diameters
Thickness
Length
Length for external pressure
Joint efficiency
Girth weld location
Longitudinal weld location angle
If you specify an outside diameter, the program will hold the outside
diameter and calculate and inside diameter based upon the calculated
required cylinder thickness. If you specify and inside diameter, the program
will hold the inside diameter and calculate and an outside diameter based
upon the calculated required cylinder thickness.
If a pipe material is specified, cylinder 24 inches and smaller, it is
recommended to input the outside diameter so that a standard pipe wall
thickness can be determined.
If check rating an existing design, specify the cylinder outside diameter or
inside diameter, thickness, length, length for external pressure, and joint
efficiency.
 Shell&TubeMech: Rear Head Cover Details
Sheet
Use this sheet to specify these rear head cover details:
Outside and inside diameters
Thickness
Forming tolerance
Joint efficiency
If check rating an existing design, specify the rear head cover outside
diameter or inside diameter, thickness, and joint efficiency. Depending on the
type of cover, other parameters may be required.
 Shell&TubeMech: Rear Head Flat Heads Sheet
If you select a rear head type that includes flat heads, use this sheet to
specify the relevant details.
Rear head flat bolted cover
If check rating an existing design, specify the following flat bolted, rear
head cover information:
Cladding thickness and clad OD (if cladded)
1st recess depth (from center)
1st recess diameter
2nd recess depth (from center)
2nd recess diameter
Rear head flat welded cover
If check rating an existing design, specify the following flat welded, rear head
cover information:
Clad thickness (if cladded)
Flat head weld attachment type
“C” factor in calculation of flat cover
 Shell&TubeMech: Rear Head S Type Sheet
If you select an S type rear head, specify the inside floating head backing:
Ring type
Recess type
If the recess type is angled-ASME, or angled TEMA style A, specify the backing
ring angle.
See Also
Backing Sheet
 Shell&TubeMech: Rear Head W Type Sheet
If you select a W type rear head, specify the type of lantern ring to be used.
If check rating an existing design, specify the lantern ring details, which
include the outer diameter, inner diameter, thickness, width, slope and
recess.
 Shell&TubeMech: Shell Cover Sheet
Use this sheet to specify a shell cover type for U-tube or floating head type
exchangers.

The default for applicable type exchangers is an ellipsoidal welded cover.

The cover can be welded directly to the shell, or it can be welded to a
separate cylinder that is welded or bolted to the shell. If the shell cover is
bolted to the shell, select Yes.
If the shell assembly is to be bolted to the tubesheet to facilitate
removable bundles, select Yes. By default the program will bolt the shell to
the tubesheet, depending on the specified TEMA rear head closure type.
 Shell&TubeMech: Shell Cover Cylinder Details
Sheet
If you are check rating an existing design with a shell cover cylinder,
specify these detail dimensions for the cylinder:
Outside and inside diameters
Thickness
Length
Length for external pressure
Joint efficiency
Girth weld location
Longitudinal weld location
 Shell&TubeMech: Shell Cover Details Sheet
Use this sheet to specify these shell cover details:
Outside and inside diameters
Thickness
Forming tolerance
Joint efficiency
If you are check rating an existing design, specify shell cover outside and
inside diameters, the thickness, and joint efficiency.
For a torispherical type shell cover, specify:
Knuckle radius, 5 or diameter
Crown radius, % of diameter
Straight flange length
Cover depth
 Shell&TubeMech: Shell Cover Flat Heads Sheet
If you select a shell cover that is a flat head type, use this sheet to specify the
relevant details.
For a flat bolted shell cover, specify:
Cladding thickness and cladding outside diameter (if cladded)
1st recess depth (from center)
1st recess diameter
2nd recess depth (from center)
2nd recess diameter
For a flat welded shell cover, specify:
Cladding thickness (if cladded)
Flat head weld attachment type
“C” factor in the calculation of the flat cover
 Shell&TubeMech: Body Flanges Sheet
Use this sheet to specify:
Tube side and shell side flange type
Select the general form of the flange. The categories refer to the shape of the
flange as found in ASME Section VIII Division 1, Appendix 2 and other
applicable construction codes.
Tube side and shell side flange design standard
For exchanger applications with shell sizes greater that 24” (610mm)
diameter, the body flanges are normally custom designed flanges, and the
program optimizes to find the best and lowest cost solution for the flange.
If you want a pre-designed, standard flange (quite often used for shells 24”
and smaller), select the appropriate standard. Note that with a pre-designed
flange, flange design calculations will not be provided because they are not
required per the code.
By default the program optimizes the design based on the applicable code.
Tube side and shell side confined joints
A flange can have different types of faces in relation to the adjoining surface.
The default is unconfined (except TEMA R).
 Shell&TubeMech: Tube Side Flange Type
Select the general form of the flange, which may be a ring flange, lap joint
flange, or hub flange.

These categories refer to the shape of the flange as found in ASME Section
VIII Division 1, Appendix 2 and other applicable construction codes.
Default: ring flange according to figure 2-4(8) of ASME, if attached to a
carbon steel cylinder or head;
lap joint flange when attached to an alloy cylinder or head.
 Shell&TubeMech: Shell Side Flange Type
Specify the general form of the flange, which may be a ring flange, lap joint
flange, or hub flange.

These categories refer to the shape of the flange as found in ASME Section
VIII Division 1, Appendix 2 or other applicable construction codes.
Default: ring flange according to figure 2-4(8) of ASME, if attached to a
carbon steel cylinder or head;
lap joint flange when attached to an alloy cylinder or head.
 Shell&TubeMech: Tube Side/Shell Side
Confined Joints
A flange can have different types of faces in relation to the adjoining surface.
The simplest form is a flat face on which the gasket seats without being
restricted radially. A confined joint forms a containment around the gasket.

Default: unconfined (except TEMA R)

 Shell&TubeMech: Individual Standards Sheet
Use this sheet to modify individual standards for
Front head flange at the cover or the tubesheet
Front shell flange
Rear shell flange
Shell cover flange
Rear head flange at the tubesheet or the cover
You can specify a design standard, code type, standard type, standard rating,
code facing, standard facing, and confined joint.
 Shell&TubeMech: Special Flange Types per
ASME Fig. 2.4
Select the code type from the list.

See Also
Individual Standards Sheet
 Shell&TubeMech: Special Flange Facing Types
per ASME Table 2.5.2
Select the code facing from the list.

See Also
Individual Standards Sheet
 Shell&TubeMech: Dimensions Sheet
Use this sheet to specify these major flange dimensions for all the flanges on
the exchanger:
Flange outside and inside diameter, bolt circle, and thickness
Gasket outside diameter, width, and thickness
Bolt diameter and number
Hub length and slope
Weld height

Body flanges can be designed per code rules or selected from standards. You
can also enter flange dimensions when executing a rating program run.
Designed flanges follow the rules dictated by the specified code. As in the case
of nozzle flanges, typical flange types available are ring, lap joint and hub
type. The program also automatically investigates the feasibility of optional
type flanges calculated as loose or integral.
If check rating an existing flange, you may specify all of the geometry
parameters listed of the existing flange or you can specify only partial
geometry data. If you are providing partial information, you must, at least,
specify all the information listed in one of the following data groups for the
flange:
Flange thickness only
Bolt diameter only
Bolt diameter and number of bolts
Gasket diameter, gasket width, gasket thickness, bolt diameter, and number
of bolts
Flange OD, bolt circle, gasket O.D., gasket width, gasket thickness, bolt
diameter, number of bolts, hub length, hub slope, and weld height (if
applicable)
All the flange geometry data listed
 Shell&TubeMech: Nubbin/Recess/Gasket Sheet
Use this sheet to specify these flange dimensions:
Nubbin width, height, and diameter
Recess depth and diameter
Overlay thickness
Gasket factor m and factor y

If check rating an existing flange, specify the nubbin width, height, and
diameter; the recess depth and diameter; the overlay thickness; the gasket m
factor and gasket seating stress, when applicable.
 Shell&TubeMech: Options Sheet
Use this sheet to specify these body flange design options:
Design temperature - flanges shell side and flanges tube side
You can set specific design temperatures for the body flanges in lieu of the
global design temperatures.
Include gasket rib area for gasket seating
The program will adjust the flange design to include the rib seating area of
the gasket (default). This assures that the flange will be able to keep the
gasket sealed for operating conditions. You may omit the gasket seating area
for the pass partition ribs for the flange calculations.
Type of bolt
You can set the bolt type to US or Metric or Din. The default is the type
applicable to the specified code and standards.
Body flange full bolt load
Per Note 2 of ASME Section VIII, paragraph 2-5(e), if additional safety is
needed against abuse or where is it is necessary to withstand the full
available bolt load, AbSa, specify Yes, for this full bolt load to be considered.
The default is standard bolt load, (Am+Ab) * Sa / 2
Minimum bolt diameter
You can specify the minimum bolt diameter to be used for the body flanges or
allow the program to select from the minimum diameters recommended by
TEMA standards.
The program default for minimum bolt diameter is 5/8” (16mm) for optimized
body flange designs. You can change that limit here for the optimized flange
design to start at a different minimum diameter. Note that you can re-set this
minimum bolt diameter limit in the Cost Database standards so that all flange
designs will use your specified limit.
Gasket unit stress
This is a secondary method to check the bolt area to assure gasket seating. If
this factor is less than the minimum Code gasket seating stress, y, the
number of bolts will be increased to assure gasket will be seating at bolt up.
This method is similar to the method in ASME (Appendix 2) that checks the
minimum bolt area. The program default is to use the applicable code method.
By selecting Yes, Shell&TubeMech determines the minimum gasket seating
stress for the flange configuration.
Gasket inner or outer metal ring width
Gaskets Minimum Contact Width
Design to satisfy flange rigidity rules
Specify Yes to have the program adjust the flange design as required to
flange rigidity rules. The default is Yes – flange will be adjusted for rigidity
rules.
Apply Rigidity Rules to Floating Head Flanges designed per Appendix 1-6(d)
KI rigidity factor
KL rigidity factor
Flange external moment
Radial load on flange
Bolt correction factor
For a pressure vessel tank design, indicate the locations where you want to
locate body flanges. Possible flange locations are at the:
Front head cover
Front shell
Rear tubesheet
Rear head cover
 Shell&TubeMech: Backing Sheet
If you are check rating an existing S type rear head, use this sheet to specify
the dimensions for the backing ring:
Flange outer diameter and inner diameter
Recess
Flange actual thickness
The default is to design a new backing ring if no dimensions are given.
You can also specify any required corrosion allowance to the outer
diameter of the floating flange and backing ring, overriding the default,
which does not apply any corrosion allowance to these surfaces.
 Shell&TubeMech: Tubesheet Sheet
Use this sheet to specify:
Tube-to-tubesheet joint type - Appendix A
Tube-to-tubesheet strength welded joint type and tube design strength, if
applicable
Tubesheet extension type
Tubesheet type
Tubesheet Tube Hole Tolerance Standard
Tube Hole Nominal Diameter
 Shell&TubeMech: Tube-to-Tubesheet Joint Type
- Appendix A
This is the type of joint used to attach the tubes into the tubesheet holes. The
simplest form is by expanding the tube wall into the holes with an expanding
tool. One or two grooves inside the tubesheet holes are sometimes used to
strengthen the attachment.

Depending on the process, users may desire to weld the tubes into the
tubesheets with a seal or strength weld in addition to expanding the tube. For
detail requirements for strength joints, see the applicable construction code
(such as UW-20 of ASME Section Div.1).
A seal or strength weld can also be used without any expansion of the tubes.
If you select partial strength, specify the tube design strength.
Default: expanded only (2 grooves)
 Shell&TubeMech: Tubesheet Extension Type
When applicable, the program evaluates the tubesheet extension against the
adjoining flange moments.

Default: extended edge for bolting depending on the type of geometry

 Shell&TubeMech: Tubesheet Type
Double tubesheets are used when it is extremely important to avoid any
leakage between the shell and tube side fluids. Double tubesheets are most
often used with fixed tubesheet exchangers, although they can also be used
with U-tubes and outside packed floating heads.

The gap type double tubesheet has a space, usually about 150 mm (6 in.),
between the inner (shell side) and outer (tube side) tubesheets.
Shell&TubeMech will provide a recommended gap.
The integral type double tubesheet is made by machining out a honeycomb
pattern inside a single thick piece of plate so that any leaking fluid can flow
down through the inside of the tubesheet to a drain. This type is rare, since it
requires special fabrication tools and experience.
Default: normal single tubesheet(s)
 Shell&TubeMech: Tubesheet Types/Welds
Sheet
Use this sheet to specify the tubesheet attachment type and tube-to-TS weld
type - UW-20.
Tubesheet attachment type
Tube-to-TS weld type - UW-20
Specify if the tube to tubesheet welds are to be considered as strength welds
per ASME, and specify the af and ag dimensions:
Fillet weld length, af - Fillet weld leg size for the tube to tubesheet welds.
Grove weld length, ag - Groove weld leg for the tube to tubesheet welds.
 Shell&TubeMech: Tubesheet Attachment Type
Select a tubesheet attachment type:

The tubesheet attachment defaults to land. This is a recess behind the

tubesheet on which the shell rests (typically 3/16" - 5 mm).
Stub end is an extension parallel to the shell axis to which the shell is
attached. This method normally requires machining of the stub end with inner
and outer radii. For an example, see ASME VIII-1 Fig. UW-13.3(c).
 Shell&TubeMech: Tubesheet
Method/Dimensions Sheet
Use this sheet to specify the tubesheet:
Tubesheet design method
Tubesheet/Cylinder optimization
Dimensions
If you specify the tubesheet design temperature on this sheet, the
program uses this temperature as the design temperature for the tubesheets
in lieu of the general shell/tube side design temperatures specified on the
Design Specifications sheet.
 Shell&TubeMech: Tubesheet Design Method
Code only
TEMA only
Code/TEMA (thicker)
Code/TEMA (thinner)
You can control which calculation method will be used to determine the final
thickness of the tubesheet(s). Code means in accordance with the selected
Design Code (jump to Design Code on Codes and Standards), in the case of
ASME VIII Div 1. this would be the UHX method.
If no method is selected, the program will use the thicker tubesheet of the
two methods. Depending on the design conditions and materials of
construction, either method may result in a thicker tubesheet. Generally the
ASME method will result in thicker tubesheets.
 Shell&TubeMech: Tubesheet/Cylinder
Optimization
Select the tubesheet/Cylinder optimization method:
Program
Program calculates the minimum required tubesheet thickness for bending
and shear. Then it checks the stresses on the tubes and cylinders (shell or
channel) welded to the tubesheet(s). If the stresses on the tubes are
exceeded, the program automatically inserts an expansion joint. If the welded
shell (i.e., BEM) or welded channel (i.e., NEN) is overstressed at the junction
with the tubesheet, the program will issue a warning.
Increase tubesheet thickness
The program increases the tubesheet thickness until all stresses are satisfied,
including adjacent components – tubes, shell, channel. This selection results
in the thickest tubesheet(s) and thinnest cylinder thickness at the junction.
Increase adjacent cylinder thickness
The program increases the shell thickness (only a small portion adjacent to
the tubesheet) and/or the channel thickness (depending of which one is
controlling) until the cylinder stresses at the junction with the tubesheet(s)
are satisfied. This selection results in the thinnest tubesheet(s) and thickest
cylinder thickness at the junction. As the cylinder thickness is increased, the
tubesheet is reinforced by the thicker cylinder welded to it, and consequently
the tubesheet thickness is automatically reduced.
If a warning message appears stating that either the shell cylinder or channel
cylinder at the tubesheet junction is overstressed, select the increase
adjacent cylinder thickness method and rerun the program. This may take a
while in some designs. If the resulting cylinder thickness adjacent to the
tubesheet is acceptable, the optimization run is finished.
If this thickness is not acceptable (too thick), fix this thickness on the
Miscellaneous sheet of the Tubesheet form. Then select increase tubesheet
thickness and rerun the program. This methodology usually results in a
tubesheet thickness less than TEMA with a somewhat thicker cylinder welded
to the tubesheet.
Note: The program automatically adjusts all the affected components
(adjacent flange geometry) during these optimizations.
 Shell&TubeMech: Tubesheet Dimensions
Specify these front and rear tubesheet dimensions on the Method/Dimensions
sheet:
Tubesheet outer diameter and thickness
Front tubesheet partition groove width and rear pass partition plate groove
width
Front tubesheet partition groove depth and rear pass partition plate groove
depth

Tubesheet cladding is typically a layer of alloy material applied to a carbon

steel base on the tube-side face of the tubesheet. If cladded, enter the front
and rear:
Clad diameter and thickness
Tubesheet cladding material, tube side
Specify how the cladding is bonded to the tubesheet base material,
explosively bonded or loose type. The type of bonding does not affect Code
calculations.
If check rating an existing exchanger, enter the tubesheet outer diameter,
and width and depth partition groove. If cladded, enter the clad diameter and
thickness and tubesheet cladding material.
 Shell&TubeMech: Recess/Corrosion Allowance
Sheet
Use this sheet to specify corrosion allowance requirements for the shell
side and tube side of the tubesheets. The values entered here override the
global corrosion allowances entered for the shell and tube sides on the Design
Specifications sheet.
You can specify any reasonable value for corrosion allowance. By default the
corrosion Allowance is obtained from the TEMA standards as follows:
For carbon steel TEMA C and , 0.0625" (1.6 mm)
For carbon steel TEMA R, 0.125" (3.2 mm)
Enter zero for no corrosion allowance. There is no default corrosion allowance
for materials other than carbon steel.
If check rating an existing exchanger, enter the these recess dimensions for
the front/rear tubesheet shell side and tube side:
Recess depth and diameter at ID gasket surface
Recess depth and diameter at OD gasket surface
A backing flange behind the tubesheet is used to avoid transferring the
flange moment caused by the adjoining flange to the tubesheet. You can
specify the front/rear backing ring flange material. When the tubesheet is
made of alloy, the backing ring flange can be made of inexpensive steel
material.
Select tubesheet tapped option to have bolt holes tapped in the rear
tubesheet instead of bolted through the tubesheet.
 Shell&TubeMech: Miscellaneous Sheet
Use this sheet to specify:
Adjacent tubesheet data
If cylinders attached to the tubesheet are of different materials and design
specifications from that of the general cylinders specifications, specify the
applicable data here.
Other
Use differential design pressure
Actual differential pressure
Load transferred from flange to tubesheet
ASME for thermal cases - use design temperature
Tube stresses at the interior of the bundle
Use flange operating bolt loads in pressure-only cases
Calculate the tubesheet flanged extension
Apply the elastic-plastic option
Design tubesheet as simply supported
ASME Code case 2499 (DL)
ASME for thermal cases - use operating loads
ASME tubesheet shear load across diameter
Display corroded and new results for UHX-13
Calculate maximum positive and negative axial expansion
Calculate the tubesheet thickness also using UG-34(c)(3)
UHX Pressure case number for detail output
UHX Load case number for detail output
 Shell&TubeMech: Double Tubesheet Sheet
If double tubesheets have been selected, use this sheet to specify any special
temperature and geometry design requirements. For any value not provided,
the program will select optimum values for design.
 Shell&TubeMech: Tube Expansion / Material
Properties Sheet
Use this sheet to specify these tube expansion parameters:
Tube Expansion Parameters
Tube expansion maximum length
Tube expansion clearance from shell face
Tube expansion clearance from channel face
Tube expansion depth ratio
Tube to tube hole friction factor
Use factor fT for expanded and welded joints
Material Properties
Tubesheet allowable stress at design temperature
Yield stress at design temperature
Modulus of elasticity at design temperature
Thermal expansion coefficient
Poisson ratio
Tubesheet material thermal conductivity
Material Properties shell cylinder adjacent to tubesheet
Allowable stress at design temperature
Yield stress at design temperature
Modulus of elasticity at design temperature
Thermal expansion coefficient
Poisson ratio
 Shell&TubeMech: Heat Transfer Data
Use the following to specify the heat transfer tube parameters:
Heat Transfer Data
If the mean metal temperatures are not known, you can provide shell and
tube coefficients, temperatures, and conductivity. From the specified data,
Shell&TubeMech estimates the actual mean metal temperatures to use in the
tubesheet and expansion joint calculations. If the mean metal temperatures
are not provided, Shell&TubeMech uses the specified design temperatures as
the mean metal temperatures.
 Shell&TubeMech: Expansion Joints Sheet
Use this sheet to specify if you want an expansion joint for the fixed
tubesheet design. Choices are:
Program - program checks and adds expansion joint if required. This is the
default.
Yes -program will add an expansion, even if one is not required.
No - the unit will be designed without an expansion joint. The program will
notify you if the unit is overstressed.
Select the expansion joint type. Aspen Shell&TubeMech defaults to the
flanged and flued type for TEMA exchangers. If a suitable joint cannot be
determined, specify the bellows type.
The program uses the specified shell mean metal temperature and the
tubes mean metal temperature to design a fixed tubesheet and expansion
joint. If not specified, the program will use the design temperatures.
The shell/tubes mean metal temperatures are very important in the correct
calculation of the relative expansion of tubes and shell. It is especially
important when the program defaults to the design temperatures because
these may not be realistic. If the Shell&TubeMech input file is generated by
Aspen Hetran, the mean metal temperatures is provided automatically, based
upon the TEMA method.
Specify the tubesheet mean metal temperature to be used in the
tubesheet design calculations. Normally, the tubesheet metal temperature is
very close to the tube metal temperature.
 Shell&TubeMech: Expansion Joint Type
The flange and flued type refers to an expansion joint with two radii. The
flanged only type has a radius only at the outer edge. The joint with the
shell is a straight angle.
The flanged type is generally the lowest cost expansion joint but is not as
flexible as the bellows type.
The bellows type, also known as a thin-wall expansion joint, has as an "S" or
toroidal shape. Typical thicknesses are less than 1/8" (3.2 mm) and made of
alloy materials. Reinforced and Toroidal bellows require extra material to
be placed on the outside of the joint to provide additional rigidity.
Toroidal bellows have a shape that provides the greatest expansion and
resistance to pressure. This type should be used when designed conditions are
extreme and other expansion joint types are not suitable.
U Welded at Crest or Root (EN code) expansion joints are covered by the
European code EN 13345. These are unreinforced U-shaped bellows of single
ply fabricated from two symmetrical half-convolutions joined by a
circumferential butt weld.
Default: Flanged and flued type for TEMA-tubesheets, and bellows for
ASME-UHX tubesheets. If a suitable joint cannot be determined, specify the
bellows type.
Notes:
The design method for the flanged type is TEMA; for the bellows type, it is
per the specified Code.

Shell&TubeMech designs thick-wall expansion joints per TEMA Section 5 and

thin-wall expansion joints per ASME-VIII-1 App. 26.
 Shell&TubeMech: Geometry Sheet
If an expansion joint is required, use this sheet to specify the dimensions.

You can also specify the maximum thickness multiplier and outer diameter
multiplier, and whether an outer cylinder is required.
If you are check rating an existing expansion joint, specify the outer cylinder
thickness, annular plate thickness, cylinder length, straight flange length,
knuckle radius
For additional information, see TEMA 1988 section 5.
 Shell&TubeMech: Corrosion Allowance/Spring
Rate Sheet
Use this sheet to specify:
Expansion joint corrosion allowance
The corrosion allowance specified here overrides the global corrosion
allowance.
Number of joints
You can specify up to two expansion joints.
Location one
This is the Zone location for the first expansion joint.
Location two
This is the Zone location for the second expansion joint.
Spring rate (corroded), Spring rate (new)
These are the bellows type expansion joint spring rates for the corroded and
new conditions. If not specified, the program will calculate the spring rate.
Expansion joint cycle life
You can specify a required life cycle, or the program will calculate the
estimated cycle life.
If you are check rating an existing joint specify the applicable corrosion
allowance, number of joints, location of first joint and second joint (if
required), spring rates (corroded, new), and the expansion joint life cycle.
 Shell&TubeMech: Bellows Sheet
If check rating an existing bellows type expansion joint, use this sheet to
specify the:
Bellows reinforcing material
Number of convolutions
Geometry details
 Shell&TubeMech: Stress Factors Sheet
Use this sheet to specify stress multipliers to adjust the allowable design
stresses used in the TEMA expansion joint calculations. If left blank, the
program uses allowable stresses recommended by TEMA.
 Shell&TubeMech: Tubes Sheet
Use this sheet to specify the tube geometry:
Number of tubes: If you do not specify the number of tubes, the program
calculates the maximum number of tubes that will fit in a given exchanger
geometry. This number varies not only with the tube diameter, pitch and
layout, but also with the type of exchanger (floating head, etc.). The default is
program calculated.
Tube length: Specify the overall tube length for straight tubes. For U-tubes
specify the tangent straight length.
Tube OD: Specify the actual dimensional outside diameter.
Tube wall thickness: The program will check if the tube wall thickness is
adequate to withstand the design pressure, both internal and external. If you
enter the average tube wall thickness, determine the minimum tube wall
based upon the manufacturing tolerance (generally in the range of 10 to
12%) and verify it is not less than the calculated required thickness for the
tubes. For low fin tubes, the tube wall thickness specified will be maintained
below the fins.
Tube type: Plain tubes do not have any enhancing type of surface on them.
Fin tubes are classified as integral low-fin types with densities of 16 to 30 fins
per inch (630 to 1181 fins per meter). Typical fin heights are 0.015 to 0.040
inches (0.4 to 1 mm). The program requires only the fin density.
Tube wall specification: Specify the tube wall specification, which appears
on the TEMA data sheet. The default is minimum wall. If you specified
average wall thickness, see tube wall thickness. The program does not adjust
the tube wall thickness based upon this average or minimum wall
specification. This option only sets a tubing requirement specification on the
data sheet.
Tube projection from tubesheet: Tube projection from the tubesheet face
should be based upon the type of attachment and any customer specification
requirements. The default is 1.5 mm or 0.625 in.
Tubes design temperature: Specify the tube design temperature, which will
determine the physical properties used in the code calculations. The default is
higher of shell and tube side design temperatures.
Tubes corrosion allowance: For most design applications no corrosion
allowance is applied to the tubes, even if you have specified a general
corrosion allowance for the shell and tube sides of the exchanger. Specify the
total corrosion (shell side and tube side) allowance required. The default is
zero corrosion allowance.
Tubes allowable design stress at design temperature: If not provided,
the program will determine the design stress based upon tube material
specified at the design temperature. You may override this calculated design
stress by entering it here. The default is the allowable design stress at design
temperature based upon material specified.
If you specify fin tubes as the tube type, you must specify the desired fin
density.
 Shell&TubeMech: Fin Tubes
If you specify fin tubes as the tube type, then you must specify the desired fin
density (the number of fins per inch or per meter depending on the system of
measure). Since the possible fin densities are very dependent on the tube
material, you should be sure that the desired fin density is commercially
available.
The dimensional standards for finned tubes made by Wolverine, High
Performance Tube, and Wieland are built into the program. If you choose one
of these, the program will automatically supply the corresponding fin height,
fin thickness, and ratio of tube outside to inside surface area. If you do not
choose one of the standard fin densities, then you must also supply the other
fin data which follows in the input.
The standard fin densities, fins/inch, for various materials are:
Tube Material Fins/Inch

Carbon Steel 19

Stainless Steel 16, 28

Copper 19, 26

Copper-Nickel 90/10 16, 19, 26

Copper-Nickel 70/30 19, 26

Nickel Low Carbon

19
Alloy 201

Nickel Alloy 400

28
(Monel)

Nickel Alloy 600

28
(Inconel)

Nickel Alloy 800 28

Hastelloy 30

Titanium 30

Admiralty 19, 26

Aluminum-Brass
19
Alloy 687

Fin height
The fin height is the height above the root diameter of the tube.
Fin thickness
The fin thickness is the average fin thickness.
 Shell&TubeMech: Baffles Sheet
Use this sheet to specify:
Baffle type, which can be divided into two general categories:
Segmental baffles, which are pieces of plate with holes for the tubes and a
segment that has been cut away for a baffle window. Single, double, triple, no
tubes in window, and disk & donut are examples of segmental baffles.
Grid baffles, which are made from rods or strips of metal that are assembled
to provide a grid of openings through which the tubes can pass. The program
covers two types of grid baffles - rod baffles and strip baffles.
Baffle orientation - horizontal, vertical, or rotated - is with respect to a
horizontal exchanger. On vertical units the baffle cut will be typically
perpendicular to the shell nozzles axes.
Bundle removal space, the bundle removal space required depends on the
specified TEMA type of the exchanger.
Bundle removal space is not applicable to fixed tubesheet designs but is
needed for removal type bundles, S / T / P / W / U rear head types.
The type of front head specified also affects the removal space needed. The A
& B front type heads are generally removed before the bundles are removed
and therefore, removable clearance for the front heads is not needed.
 Shell&TubeMech: Baffle Type
Baffle types can be divided up into two general categories:
Segmental baffles
Grid baffles
Segmental baffles, the most common type of baffle, are pieces of plate with
holes for the tubes and a segment that has been cut away for a baffle window.
Single, double, triple, no tubes in window, and disk & donut are examples of
segmental baffles, with the single segmental baffle being the type used in a
majority of shell and tube heat exchangers.

The baffles should have at least one row of overlap, and therefore become
practical for a 20 mm or 0.75 in. tube in shell diameters of 305 mm (12 in.)
or greater for double segmental and 610 (24 in.) or greater for triple
segmental baffles.
Note: The Aspen EDR triple segmental baffle is different than the TEMA triple
segmental baffle.
Full supports are used in K and X type shells where baffling is not necessary
to direct the shell side flow.
No tubes in window is a layout using a single segmental baffle with tubes
removed in the baffle windows. This type is used to avoid tube vibration and
may be further enhanced with intermediate supports to shorten the
unsupported tube span. The standard abbreviation for no tubes in the window
is NTIW.
Grid baffles are made from rods or strips of metal that are assembled to
provide a grid of openings through which the tubes can pass. The program
covers two types of grid baffles - rod baffles and strip baffles.
Rod baffle design is based on the
construction and correlations developed
by Phillips Petroleum. Rod baffles are
limited to a square tube pattern. The
rods are usually about 6 mm (0.25 in.) in
diameter. The rods are placed between
every other tube row and welded to a
circular ring. There are four repeating
sets where each baffle is rotated 90
degrees from the previous baffle.
 Strip baffles are normally used with a
triangular tube pattern. The strips are
usually about 25 mm (1 in.) wide and 3
mm (0.125 in.) thick. The strips are
placed between every tube row.
Intersecting strips can be notched to fit
together or stacked and tack welded.
The strips are welded to a circular ring.
Strip baffles are also sometimes referred
to as nest baffles.

Default: single segmental except X shells; full support for X shell

See Also
Baffles Sheet
 Shell&TubeMech: Baffle Details Sheet
Use this sheet to specify these baffle details:
Baffle cut in percent of vessel diameter: The baffle cut is based on the
percent of shell diameter. Typically 15% to 45%, depending on flow
parameters and type of baffle (single vs. double vs. triple segmental or no-
tubes-in-window). For double-segmental baffles, the baffle cut is the size of
the inner window divided by the shell diameter X 100. For triple-segmental
baffles, the baffle cut is the size of the innermost window divided by the shell
diameter X 100. For nests or rod baffles, there is no baffle cut (leave blank or
zero).
Baffle number: Number of transverse baffles including full supports when
applicable. The number of baffles applies to all transverse baffles and full
supports. It should include the full support(s) under the nozzle(s) on a G, H,
or J type shell. It should not include the full support at the beginning of the u-
bend of a u-tube bundle.
Baffle spacing: Specify the center-to-center baffle spacing. This number and
the number of baffles are complementary. If not entered, the program will
determine the inlet and outlet baffle spacing.
Baffle inlet spacing: Specify the baffle spacing at the inlet nozzle. If not
entered, the program will set based upon the center to center spacing and
outlet spacing if specified. If the outlet spacing is not specified, the program
will set the inlet and outlet spacing the same based upon available tube
length.
Baffle outlet spacing: Specify the baffle spacing at the outlet nozzle. If not
entered, the program will set based upon the center to center spacing and the
inlet spacing if specified. If the inlet spacing is not specified, the program will
set the inlet and outlet the spacing the same based upon available remaining
tube length.
Baffle thickness: Specify the actual thickness of the baffles. The default is
TEMA standards.
Baffle diameter: Specify the actual baffle outside diameter. The default is
TEMA standards.
Unsupported tube span: Normally you allow the program to calculate the
unsupported tube span based upon the baffles spacing. If you specify an
unsupported tube span, Aspen Shell&TubeMech uses this value in lieu of the
program value in the TEMA fixed tubesheet calculations.
Unsupported tube span Factor k: Enter the unsupported tube span k factor
used to determine the Cc variable in the TEMA tube compressive stress
calculations, if you want to override the program calculated k factor.
Baffle Tube Hole Diameter
 Shell&TubeMech: Double/Triple Cuts Sheet
Use this sheet to specify double baffle and triple segmental cuts. The baffle
cut is based on the percent of shell diameter.
For more information on double and triple segmental baffle cuts, see the
Appendix.
 Shell&TubeMech: Tubesheet Layout Sheet
Use this sheet to specify:
Tube pattern
The tube patternis the layout of the tubes in relation to the shell side
crossflow direction, which is normal to the baffle cut edge. The default is 30
degrees.
Tube pitch
This is the center-to-center distance between adjacent tubes within the tube
pattern. The default is the minimum recommended by TEMA.
Tube passes
Specify the number of tube passes.
Tube pass layout type
This is the layout of the tubes for four or more passes.
Impingement protection type
The purpose of impingement protection is to protect the tubes directly under
the inlet nozzle by deflecting the bullet shaped flow of high velocity fluids or
the force of entrained droplets.
Outer tube limit diameter
The outer tube limit (OTL) is the diameter of the circle beyond which no
portion of a tube will be placed. If you specify an OTL, the program
determines the maximum number of tubes that will fit. If no OTL is specified,
the program calculates the OTL based upon the specified shell diameter and
TEMA standard bundle clearances. By default the program calculates the OTL.
Layout option
You can select to have the program generate a new tube layout for each run
(default), or you can select to use an existing layout. For the second option,
you must first run Shell&TubeMech to establish a layout and then select the
option to use the existing layout for all subsequent runs.
 Shell&TubeMech: Tube Pass Layout Type
There are several possible ways to layout tubes for four or more passes.
Quadrant layout has the advantage of
usually (but not always) giving the highest
tube count. It is the required layout for all
U-tube designs of four or more passes. The
tube side nozzles must be offset from the
centerline when using quadrant layout. The
program automatically avoids quadrant
layout for shells with longitudinal baffles and
6, 10, or 14 pass, to avoid having the
longitudinal baffle bisect a pass.

Mixed layout has the advantage of keeping

the tube side nozzles on the centerline. It
often gives a tube count close to quadrant
and sometimes exceeds it. The program
automatically avoids mixed layout for shells
with longitudinal baffles and 4, 8, 12, or 16
passes.

Ribbon layout nearly always gives a layout

with fewer tubes than quadrant or mixed
layout. It is the layout the program always
uses for an odd number of tube passes. It
is also the layout preferred by the program
for X-type shells. The primary advantage of
ribbon layout is the more gradual change in
operating temperature of adjacent tubes
from top to bottom of the tubesheet. This
can be important when there is a large
change in temperature on the tube side,
which might cause significant thermal
stresses in mixed and quadrant layouts.

Default: program will optimize

 Shell&TubeMech: Impingement Protection Type
The purpose of impingement protection is to protect the tubes directly under
the inlet nozzle by deflecting the bullet shaped flow of high velocity fluids or
the force of entrained droplets. TEMA recommends that inlet impingement
protection be installed under the following conditions:
when the rho*V² through the inlet nozzle exceeds 2232 kg/(m*s²) or 1500
lb/(ft*s²) for non-corrosive, non-abrasive, single phase fluids
when the rho*V² through the inlet nozzle exceeds 744 kg/(m*s²) or
500 lb/(ft*s²) for corrosive or abrasive liquids
when there is a nominally saturated vapor
when there is a corrosive gas
when there is two phase flow at the inlet

If you choose a plate on the bundle the program automatically removes

tubes under the inlet nozzle so that the shell entrance area equals the cross-
sectional area of the nozzle. This is approximately equal to removing any
tubes within a distance of 1/4 the nozzle diameter under the center of the
nozzle. The program default uses a circular impingement plate equal in
diameter to the inside diameter of the nozzle, and approximately 3 mm or 1/8
in. thick.
An alternative is to put a plate in a nozzle dome, which means suspending
the impingement plate in an enlarged nozzle neck, which may be a dome or a
cone.
 Shell&TubeMech: Details/Pass Partitions Sheet
Use this sheet to specify tubesheet layout details and pass partitions details.
You can specify these tubesheet layout details:
Max deviation per pass in percent
The program defaults to 5% maximum deviation per pass when calculating
how many tubes can fit in a given pass.
Degree of symmetry
If specified, the program will attempt to put the same number of tubes per
pass. If not specified, the program will optimize as many tubes as possible in a
given configuration.
Min U-bend Diameter
The program default is 3 times the tube OD.
You can specify the following detailed information about the pass partitions:
Pass partition lane clearance
Allowable pressure drop across the partition plate
Pass partition corrosion allowance
Front (top) pass partition plate thickness
Front head pass partition rib length and width
Pass partition dimension ‘a’ and pass partition dimension ‘b’ (TEMA
standards).
 Shell&TubeMech: Tie Rods/Spacers Sheet
Use this sheet to specify tie rod and tie rod spacer information.
You can specify the following tie rod information:
Number of tie rods
Diameter and length of the tie rod
Tie rod material
You can specify the following for the information for the tie rod spacers:
Number of spacers
Diameter and thickness of the spacer
Spacer material
 Shell&TubeMech: Drawing Sheet
Once you have run the Shell&TubeMech program and have mechanical design
results, you can interactively make modifications to the tube layout.
Tubes: Tubes can be removed from the layout by clicking on the tube to be
removed (tube will be highlighted in red) and then selecting the red X in the
menu. If you want to designate a tube as a plugged tube or as a dummy tube,
click on the tube (tube will be highlighted in red) and then select the plugged
tube icon or dummy tube icon from the menu.
Tie Rods: To remove a tie rod, click on the tie rod (tie rod will be highlighted
in red) and then select the red X in the menu. To add a tie rod, select the add
a tie rod icon in the menu and then specify the location for the tie rod.
Sealing Strips: To remove a sealing strip, click on the sealing strip (sealing
strip will be highlighted in red) and then select the red X in the menu. To add
a sealing strip, select the add a sealing strip icon in the menu and then
specify the location for the sealing strip. Once you have completed your
changes to the tube layout, you may want to elect to fix the layout for
subsequent Shell&TubeMech runs by selecting the "Use existing layout"
option located on the Tubesheet Layout tab.
 Shell&TubeMech: Shell Side & Tube Side
Nozzles Sheets (General)
Use the Shell Side sheet and Tube Side sheet to specify the following
information:
Nozzle flange design
Select the design. ISO or DIN standards can be referenced. Also an optimized,
program calculated flange, may be selected.
Nozzle elevation above vessel wall
Specify the nozzle elevation from vessel centerline to face of nozzle.
Couplings on nozzles
Select number of couplings to be provide in each nozzle. The default is TEMA
standards.
Nozzle flange rating
Select the flange rating. The default is to select a flange rating in accordance
with the applicable specified code.
Nozzle flange type
Select the nozzle flange type from the list. The default is slip on type.
Code flange type
For code calculated flanges, select a flange type for the optimized nozzle
flange.
Nozzle flange facing
Select raised or flat face type. The default is flat face.
Code flange face type
Select facing type for a calculated nozzle flange. The default is a flat facing.
 Shell&TubeMech: Nozzles & Couplings Sheets
Use the Nozzles sheet and Couplings sheet to specify the following
information:
Name
Specify the identification of each nozzle for the drawings and text output.
Program default starts with the letter A through J.
Description
You can provide a description for each nozzle that will appear in the text
output.
Function
Select the function of nozzle, such as inlet, outlet, vent, drain. Note that by
identifying the inlet nozzles, the program locates impingement plates if one
has been specified.
Type
For couplings only, select the coupling design rating.
Diameter
Specify the nominal diameter of nozzle. If actual diameters are specified, the
program selects the closest standard nozzle diameter per the applicable code.
Program determines actual diameter from the application pipe standards.
Location
Specify a zone location for the nozzle or coupling. This is an approximate
location from which the program will calculate the actual dimensional
location. Specify a general zone location for the nozzle, zones 1 and 2 for
front head nozzles, zones 3 through 7 for shell nozzles, and zones 8 and 9 for
rear head nozzles. Nozzles should be located in accordance with the TEMA
type of shell that you have selected. Note that the specified zone locations
override standard TEMA locations.
Angle
Specify the angle location. For example a nozzle located at the 45 degree
points (i.e. 0, 45, 90, 135 ….) will be oriented radially to the cylinder. All
other angles result in the nozzle being located hill side on the cylinder.
 Shell&TubeMech: Domes/Distributor Belts
Sheet
Use this sheet to specify dome and distributor belt information. In design
mode, the program will calculate (or use defaults) for the following
dome/distributor information, if program is selected.
Dome type
Select the type of dome: ellipsoidal (default), torispherical, conical, or
distributor belt.
Dome diameter
Specify the outside diameter of the dome cylinder.
Dome location
Specify the zone location for the dome at the same location as the location for
the attaching nozzle.
Dome angle
Specify the angle for the dome as the same for the attaching nozzle.
Dome thickness
Specify the thickness for the dome. The default is program calculated.
Dome cylinder thickness
Specify the thickness for the cylinder attached to the dome. The default is
program calculated.
Dome attachment type
Select the weld attachment type to vessel. The default is program selected.
Reinforcing pad
If pad is to be provided, specify the OD and thickness. The default is added by
program if required.
Weld leg
Weld size for the dome to vessel attachment weld. The default is program
calculated.
Distributor belt type
Select type from ASME appendix 9.
Knuckle radius
Specify the knuckle radius for flanged and flued type distributor belt. The
default is program selected.
If you are running in the check rating mode, specify the information required,
as applicable.
 Shell&TubeMech: Nozzle Cylinders/Re-Pads
Sheet
In design mode, the program calculates (or uses defaults for) the following
nozzle detail information:
· Nozzle Cylinder Thickness
· Nozzle Reinforcing Pad Outside Diameter
· Nozzle Reinforcing Pad Thickness
· Nozzle Reinforcing Parallel Limit – the reinforcing limit in the
direction of the shell axis, used in the nozzle reinforcement calculation
· Nozzle Reinforcing Perpendicular Limit – the reinforcing limit in the
direction of the nozzle, used in the nozzle reinforcement calculation
· JE for A5 – the joint efficiency applied to a welded split repad ring

In check rating mode, specify the nozzle-related information, as applicable.

 Shell&TubeMech: Nozzle
Projection/Elevation/Distances Sheet
Use this sheet to specify the nozzle projection, elevation, and distances
details. In design mode, the program calculates (or uses defaults) for the
following nozzle detail information:
Type attachment
Select the type of nozzle attachment to the vessel from the list
Weld leg height, Nozzle
Specify the weld leg height at the nozzle attachment to the cylinder at the
outside surface.
Weld leg height, Internal Projection
Specify the weld leg height of the nozzle attachment to the vessel cylinder at
the nozzle projection into the vessel.
Weld leg height, Re Pad
Specify the weld leg height at the reinforcement pad.
Projection
Specify the projection of the nozzle into the vessel from the inside surface.
The program default is having the nozzles flush with the inside vessel surface.
Elevation
Specify the distance the nozzle extends beyond the vessel OD. The elevation
above the vessel wall defaults to a minimum of 6" (152 mm). The user can
enter values to clear the thickness of insulation, if present.
Distance from nozzle centerline, Gasket
Specify the distance from nozzle center line to from tubesheet gasket face.
Nozzle distance from nozzle centerline head
Specify the distance from nozzle center line to centerline of front head
nozzles.
Offset distance, Nozzle
As an alternate to specifying the angle location for an offset nozzle (Nozzles-
General form, Nozzles sheet), you can specify the offset distance from the
nozzle centerline tot he vessel centerline.
In check rating mode, specify the nozzle-related information, as applicable.
 Shell&TubeMech: Nozzle Flanges & Nozzle
Clearances Sheets (Details)
Use the Nozzle Flanges sheet and the Nozzle Clearances sheet to specify the
nozzle flanges details. In design mode, the program calculates (or uses
defaults) for the following information:
Nozzle flange standard
The nozzle flanges can be designed or selected from standards.
Nozzle flange type
The nozzle flange types in ASME follow the ANSI B16.5 standard including
long weld neck types (thicker necks).
Nozzle flange rating
You can select a flange rating or allow the program to determine the
appropriate rating based on materials of construction and the design pressure
and temperature of the flanges per applicable standards (ANSI, DIN, or
AFNOR). The default is to allow the program to determine flange rating per
applicable standards.
Nozzle face
Select the nozzle facing type. The default is flat face.
Nozzle clearances
The inputted clearances are used to locate the nozzle according to these rules
(the largest calculated total clearance is used by the program to locate the
nozzle):
· Clearance TS nozzle flange to body flange or tubesheet - Dimension B =
Nozzle flange radius + inputted clearance (default 1")
· Clearance SS nozzle flange to body flange or tubesheet - Dimension A =
Nozzle flange radius + inputted clearance (default 1")
· Clearance reinforcement pad weld to adjacent component - Dimension C
= (Parallel limit) or (repad radius + weld) + inputted clearance (default 1")
· Clearance nozzle weld to adjacent component - Dimension D = Nozzle
outside radius + weld + inputted clearance (default 1")
The final nozzle location depends on any adjacent components between the
nozzle and the reference point. The adjacent component thickness, if any, is
added to the nozzle location distance.
The above clearances are not used if the user enters the exact nozzle
location.
Nozzle Reinforcement Ring Design (Shell Side and Tube Side)
Default is Yes. The program uses a reinforcing ring if additional nozzle
reinforcement is required. If you select No, the program increases the nozzle
thickness in an attempt to provide enough nozzle reinforcement without using
a reinforcing ring. The program might not be able to find a thick enough
nozzle wall, so a reinforcing ring might still be required.
Appendix 1-10 Alternative Design Method
Alternative Method for Design of Reinforcement for Large Openings in
Cylindrical Vessels Under Internal Pressure
Default is No. Applicable only to large openings (see ASME code for
definition). If you select Yes, the program designs nozzles per App. 1-10, as
applicable under the large nozzle definition.
Angle for nozzle per Appendix 1-10
Default is Perpendicular. Only applicable if Appendix 1-10, alternative
design method, is selected. If the nozzle is oriented at an angle from the shell
longitudinal axis, you can enter that angle in the applicable input cell.
100% Metal Replacement in Pad
Default is No. The User can select:
Uncorroded Metal
Corroded Metal
Selecting these options instructs the program to take the opening area
(diameter x vessel wall thickness, new or corroded) and apply this area as a
reinforcing ring around the nozzle (equal halves).
Nozzle reinforcement per App. 1-9
Alternative rules for reinforcement of openings under internal pressure
Default is No. If you select Yes, the program designs nozzles per App. 1-9, as
applicable.
 Shell&TubeMech: Nozzle Flange Type

The nozzle flange types in ASME follow the ANSI B16.5 standard, including
long weld neck types (thicker necks). If you do not want separate reinforcing
plates, self-reinforced nozzle styles 'H' and 'S' are also available. Style 'S'
provides a thicker neck at the junction to the vessel than style 'H' which also
provides a thicker neck than a long weld neck.
 Shell&TubeMech: External Loads Sheet
Use this sheet to specify external loads and moments information. In design
mode, the program calculates (or uses defaults) for the following nozzle detail
information:

In the check rating mode, specify the nozzle-related information, as

applicable.
Nozzle external loads: To evaluate external piping loads to WRC-107, enter
loads and moments as indicated.
 Shell&TubeMech: Horizontal Sheet
Use this sheet to specify:
Support type - horizontal
The program analyzes the shell stresses caused by supports in both the
horizontal (saddles). For saddles the program uses the method developed by
L.P.Zick. When this method indicates an over-stressed condition, the program
warns the user. Typical locations and angle for saddles are 4 and 6 and 180
degrees. Other angles are only used for stacked exchangers (zero degrees).
Calculation methods for supports for stacked exchangers are not yet
available.

Saddle support A location

Specify general zone (zones 3 or 4) location for the front saddle support.
Saddle support B location
Specify general zone (zones 6 or 7) location for the rear saddle support.
Saddle support location angle
Specify angle location for the saddle supports (180 degrees for bottom
supports or 0 degrees for top support with stacked units).
Distance from face of front tubesheet to bolt hole in support A
You can specify the actual dimensional location of the front support from the
front tubesheet.
Distance from face of front tubesheet to bolt hole in support B
You can specify the actual dimensional location of the rear support from the
front tubesheet
Distance from bolt hold in support A to nearest stiffening element
This will define the nearest shell stiffening element to be considered in the
Zick support analysis.
Distance from bolt hold in support B to nearest stiffening element
This will define the nearest shell stiffening element to be considered in the
Zick support analysis.
Load on Saddles
You can specify dead weight loads for the Saddle ‘A’ and Saddle ‘B’ supports.
Program uses these values in lieu of the calculated loads based on the full
weight of the vessel.
 Shell&TubeMech: Details Sheet
Use this sheet to specify your own design for the saddle supports.

Saddle to shell
The angle of contact is normally set at
angle of
120 degrees.
contact

Support This is the projection of the saddle

elevation support from the vessel centerline.

Plate thickness varies from 0.25 inches

Wear plate
up to the thickness of the shell cylinder.
thickness
Program defaults to no wear plate.

Base plate The normal thickness ranges from 0.5

thickness inches to 2 inches.

Base plate Any width is accepted up to the

width diameter of the shell.

Base plate The normal depth is from 4 inches to 12

depth inches.
 Shell&TubeMech: Gussets/Bolts Sheet
Use this sheet to specify the gussets and bolt hole information for your
design.

Gusset thickness ranges from 0.375

Gusset thickness
inch to 1 inch.

Gusset number
Ranges from one to four gussets.
per support

Supports opened towards the center

Gusset direction of the vessel or outward towards the
ends of the vessel.

Size ranges from 0.625 inch to 3 inch

Bolt holes
allowing for 1/8 inch clearance to bolt
diameter (dh)
diameter.

Bolt distance
Allow a minimum of 2 times the bolt
edge to x axis
hole size.
(ce)

Bolt center to
Any dimension less than the diameter
center distance
of the vessel.
(cc)

Bolt slot length Generally the slot is 2 times the bolt

(lh) hole diameter.

Bolt quantity Normal ranges from 2 to 8 bolts.

 Shell&TubeMech: Stacked Units Sheet
Use this sheet to specify the number of stacked exchangers, up to four units.
The detailed drawings include a sketch showing the stacking arrangement for
the exchangers. However, you will need to evaluate the vessel support design
for base and intermediate supports.
Note that it is possible to input a total weight for the stacked exchangers, and
the program will design the base support using this total weight. The program
also uses the base support design for the intermediate supports.
 Shell&TubeMech: Vertical Sheet
Currently the program provides a design for vertical lug type supports. The
program analyzes the shell stresses caused by vertical (lugs) positions. For
vertical lug supports the program will calculate the required lug weld height
to avoid over-stressing the shell. Calculations methods for (3) vertical ring
supports are not yet available.

Use this sheet to specify the following vertical support information:

Support type- vertical
Specify type of vertical vessel support type. From two to four lug type
supports can be specified. The vertical ring type is a single continuous ring
around the shell. Calculations for the ring type are not yet available.
Support location- vertical
Specify general zone location (zones 3 through 7) for the support.
Distance from tubesheet to support
Specify the distanced from the tubesheet to the bolt hole in the support.
Vertical Support angles
Specify the angle location for the lug type supports, for example, 180 degrees
apart for two lugs and every 45 degrees for 4 lugs.
 Shell&TubeMech: Lugs Sheet
Use this sheet to specify your own design details for the saddle supports:
Plate thickness varies from 0.25
Wear plate inches up to the thickness of the
thickness shell cylinder. Program defaults to no
wear plate.

Base plate Normal thickness ranges from 0.5

thickness inches to 2 inches.

Base plate Any width is accepted up to the

width diameter of the shell.

Base plate Normal depth is from 4 inches to 12

depth inches.

Gusset Gusset thickness ranges from 0.375

thickness inch to 1 inch.

Gusset
The number ranges from one to four
number per
gussets.
support

Diameter size ranges from 0.625 inch

Bolt holes
to 3 inch, allowing for 1/8 inch
diameter
clearance to bolt diameter.

Bolt distance Allow a minimum of 2 times the bolt

edge to x axis hole size.

Bolt center to
Specify any dimension less than the
center
diameter of the vessel.
distance

Bolt quantity Quantity ranges from 2 to 8 bolts.

 Shell&TubeMech: Lift Lugs Sheet
Use this sheet to specify the following information:
Lifting Lugs
Lug type is plate type.
type

Specify number of unit lifting lugs required.

Default is 2. These are placed to form an
angle of 30° between the horizontal axis
and the lifting line when both lifting lugs
are used simultaneously.

Number to
lift the
whole unit

Specify the zone location for each lug. For

the lugs lifting the whole vessel on the
shell, default location will be 4 and 6.
A Lug at location 2 will indicate to the
program to design a lug for the front
Location of channel.
each Lug A lug at location 8 will indicate to the
program to design a lug for the rear
channel.
A maximum of 3 lug calculations can be
performed. Location settings are similar to
nozzle placement

Specify the angle for each lug. Default is 0

Angle of
degrees (top). Orientation angles are
each Lug
similar to nozzle placement.

Lifting Lugs
Specify material for lug.
Material

Lifting Lugs
Re-pad Specify the reinforcement pad material.
material
 Shell&TubeMech: Lift Lugs Geometry Sheet
Use this sheet to specify the lug geometry:
h Weld height of the attachment weld

Length of the attachment weld to the

l
vessel

p Thickness of reinforcement pad

r Radius of lug hole

t Thickness of the lug

Height from vessel wall to centerline of

H
hole

L Length of reinforcement pad

R Radius of lug at top

W Width of reinforcement pad

 Shell&TubeMech: Material Specifications Sheet
Use this sheet to specify materials for required components. You can use the
generic material types such as carbon steel (default), and the program will
assign actual default material specifications depending on the product form.
For carbon steel plate, a material specification of SA-516-70 is used for an
ASME design. Appropriate specifications are selected for other design
construction codes.
To search for a specific material specification, click the Search Databank
button. Type the first few characters to search for a material in the databank.
Click the Advanced tab to view additional detailed information about the
materials in the database.
The Advanced search mode is especially useful to view special ASME material
notes. ASME, per the 2002 addendum, allows higher secondary stress limits if
(a) the allowable stress for the material is not governed by time-dependent
properties as stated in the notes, (b) the ratio of minimum yield to minimum
tensile, at room temperature, is less than 0.7, (c) the yield strength at
temperature is available from Table Y-1of Section II, Part D.
You can use the DefMats utility to change the default materials.
See Also
Generic Materials List
 Shell&TubeMech: Normalized Materials Sheet
Use this sheet to specify that all carbon steel materials be normalized per Fig.
UCS-66. The program default is to normalize materials when required by the
applicable design code.
 Shell&TubeMech: Nozzle Materials Sheet
Use this sheet to specify nozzle materials for required components. The
materials specified here apply globally. You can use the generic material types
such as "carbon steel" which the program will assign an actual default
material specifications depending on the product form. For carbon steel pipe
material, a material specification of SA-106-B will be used for an ASME
design. Appropriate specifications will be selected for other design
construction codes.
To search for a specific material specification, click the Search Databank
button. Type the first few characters to search for a material in the databank.
You can use the DefMats utility to change the default materials.
Default: carbon steel
See Also
Generic Materials List
 Shell&TubeMech: Nozzle Individual Materials
Sheet
Use this sheet to specify materials for specific nozzles. Any materials specified
on this sheet override global settings.
Identify each nozzle for the drawings and text output. The program default
starts with the letter A through H. For each nozzle specify:
The nominal pipe size for the diameter.
If actual diameters are specified, the program selects the closest standard
nozzle diameter per the applicable code. Program determines the actual
diameter from the application pipe standards.
Generic or actual material specification for the cylinder material, nozzle
reinforcing pad material, flange, gasket, and bolting.
If not specified, the program sets the materials to the default, carbon steel.
You can use the generic material types such as "carbon steel" and the
program will assign actual default material specifications depending on the
product form. For carbon steel pipe, a material specification of SA-106-B will
be used for an ASME design. Appropriate specifications will be selected for
other design construction codes.
To search for a specific material specification, click the Search Databank
button. Type the first few characters to search for a material in the databank.
You can use the DefMats utility to change the default materials.
See Also
Generic Materials List
 Shell&TubeMech: Dome/DB Materials Sheet
Use this sheet to specify the dome and distributor belt formed and cylinder
materials and dome reinforcement material. Enter the material in the same
order as the nozzles on the domes.
To search for a specific material specification, click the Search Databank
button. Type the first few characters to search for a material in the databank.
See Also
Generic Materials List
 Shell&TubeMech: Couplings Materials Sheet
Use this sheet to specify the shell side and tube side couplings material.
To search for a specific material specification, click the Search Databank
button. Type the first few characters to search for a material in the databank.
See Also
Generic Materials List
 Shell&TubeMech: External Loads/Code Cases
Sheet
Use this sheet to specify the external nozzle attachments loads, and they will
be analyzed per the Welding Research Council Bulletin, WRC-107. If the
nozzle loads are not known but you need the allowable loads based upon your
final design, select the Heat Exchange Institute, HEI, method for external
nozzle loads and the allowable loads will be calculated.
 Shell&TubeMech: Wind Loads Sheet
Use this sheet to specify the following wind load information in accordance
with ANSI/ASCE 7-95. Refer to this standard for more details of the method
used.
Vessel Effective Length and Diameter
If a value is required that differs from the value calculated by the program,
enter the effective length and/or diameter of the vessel.

Equipment Occupancy Category – Wind Design

Category l – low hazard to human life
Category ll – equipment not included in categories III and IV
Category lll – substantial hazard to human life if failure occurs
Category lV – essential facilities
The default is Category ll

Velocity Pressure Exposure Coefficient, Kz

Default = 1 (Exposure C at 33 feet (10m))

Topographic Factor, Kzt

Default = 1

Directionality Factor, Kd
Default = 1

Basic Wind Speed, V

The default is 160 km/hr (100 mph) wind load.

Importance Factor, I
Default = 1

Gust Response Factor, G

Default = 0.85
Force coefficient, Cf
Default = 1

Moment arm
If a value is required that differs from the value calculated by the program,
enter the distance from the center-of-gravity to the base of the supports.

To apply the wind loads to the supports or to the body flanges, click the
Seismic Loads tab, and select Yes to apply wind and seismic loads to supports
and /or body flanges.
 Shell&TubeMech: Seismic Loads Sheet
Use this sheet to specify the following wind load information in accordance
with ANSI/ASCE 7-95. Refer to this standard for more details of the method
used.

Vessel Effective Length and Diameter

If a value is required that differs from the value calculated by the program,
enter the effective length and/or diameter of the vessel.

Equipment Occupancy Category

Category l – low hazard to human life
Category ll – equipment not included in categories III and IV
Category lll – substantial hazard to human life if failure occurs
Category lV – essential facilities
The default is Category ll

Seismic Site Classification

Refer to ANSI/ASCE 7-95, table 20.3-1. Default is site class B

Seismic Load Importance Factor, I

Default = 1

Vessel Amplification Factor, Ap

Default = 1

Seismic Spectral Response Acceleration at short periods, Ss

Default = 0.5g

Seismic Spectral Response Acceleration at one second, S1

Default = 0.2g

Seismic Response Modification Factor, R

Default = 3
Height Ratio z/h
Default = 0.5

Apply Wind and Seismic Loads to Supports

If the magnitude of the Wind or Seismic Loads is such that their effect should
be considered in the design of the supports, then select the appropriate value.
By default external loads not applied to supports.

Apply Wind and Seismic Loads to Body Flanges

If the magnitude of the Wind or Seismic Loads is such that their effect should
be considered in the design of the body flanges, then select the appropriate
value.
By default external loads not applied to body flanges.
 Shell&TubeMech: Weights Sheet
Use this sheet to specify exchanger weights. The weights specified here:
Override the program calculated weights
Are used for the vessel support analysis
Appear on the drawings
The support analysis applies one half of the full weight to each support. If
support loads have been specified in the vessel support sections, those loads
override what is specified here.
If weights for accessories or attachments (interconnecting shell and tube side
piping) are specified, they are used in the vessel support stress analysis.
When Insulation is required, the weight of the insulation is added to the total
weight of the unit. If insulation is required but you did not specify the details
for the insulation, Shell&TubeMech sets the thickness to 2.5” with a density of
8 Lb/ft3. If insulation thickness is specified, Shell&TubeMech checks and
adjusts the nozzle projections to clear the insulation. The default is set to
“no” insulation.
Shell side and tube side fluid densities are used for the determination of the
liquid weight inside the exchanger. If no densities are specified, the density of
water is used for weight calculations.
 Shell&TubeMech: Drawings
Use the Drawings sheet to select the drawings to be generated when the
program runs. You can also specify a title for the drawing number.
 Shell&TubeMech: CODAP and AD Codes
If the v essel is being designed to CODAP or AD code, use the sheets of the
CODAP and AD Codes form to define the necessary construction categories,
safety factors, and design factors.
 Shell&TubeMech: Using the Change Codes Form
Use the Aspen Shell&TubeMech Change Codes form to specify change codes
with the associated values.
The format for change code entries is: CODE=value
Change codes are processed after all of the other input and override any
previously set value. For instance, if you specify the tube outside diameter as
20 mm in the regular input screens, then enter the change code TODX=25,
the 25 will override the 20. If you enter the same change code more than
once, the last value will prevail.
Another good use of the change code screen is to "chain" to another file
containing only change codes. This is especially convenient if you have a line
of standard designs, which you want to use after you have found a similar
solution in design mode.
To do this, use the FILE= change code, followed by the name of the file
containing the other change codes. The other file must also have a .BJI
filetype. You can create this change code file with a standard edit program.
For example, the entry FILE=S-610-2 would point to a file named S-610-
2.BJI, which might contain the following data:
SODX=610,TLNG=5000,TNUM=458,TPAS=2,BSPA=690,TODX=20,TPAT=1
These are the change codes that are available in the Aspen Shell&TubeMech
program.
See Also
General Change Codes
Cylinders & Covers Change Codes
Nozzles Change Codes
Body Flanges Change Codes
Floating Head Flange Change Codes
Tubesheets & Expansion Joint Change Codes
Supports Change Codes
Dimensions Change Codes
 Shell&TubeMech: General Change Codes
These are the general change codes that are available in the Shell&TubeMech
program:

Code Description

bttk baffle thickness

cfac "C" factor in calculation of flat covers

conical head angle (must be less than or equal

coan
to 30 degrees)

code requirement: 1=ASME, 2=CODAP,

code
3=AD/DIN

elra radius of turn for 90 degree elbow

front head cylinder girth butt welds present:

fcgw
0=no, 1=yes

fhct front head flat removable cover thickness

specify the name of a file which contains change

file
codes

joint efficiency for shell side cylinders for nozzle

jess
repad calcs

joint efficiency for tube side cylinders for nozzle

jets
repad calcs

language for input and output:

lang 1=English, 2=French, 3=Spanish, 4=German,
5=Italian

meas system of measure: 1=U.S., 2=SI, 3=metric

no drawings in Shell&TubeMech summary

nodr
output: 0, 1=yes, 2=no

otlm outer tube limit

total length of pass partition ribs in front/rear

rblf/rblr
head

stiffening ring material / number of stiffening

srmt/stf1
rings

effective width of pass partition ribs in front

rbwf
head

rbwr effective width of pass partition ribs in rear head

rear head cylinder girth butt welds present:

rcgw
0=no, 1=yes

rhct rear head flat removable cover thickness

 shell cover cylinder girth butt welds present:
scgw 0=no, 1=yes

CODAP construction category shell side: 1=A,

scat
2=B, 3=C, 4=D

shgw shell girth butt welds present: 0=no, 1=yes

shje shell joint efficiency (ASME)

sjef CODAP joint efficiency on shell side (0.85 or 1)

sstp shell side test pressure

ssto shell side tolerance for plate

tubesheet considered supported: 0=program,

suts
1=yes, 2=no

CODAP construction category tube side: 1=A,

tcat
2=B, 3=C, 4=D

tjef CODAP joint efficiency on tube side (0.85 or 1)

determines if input thickness of pipe is:

tkmn
0=nominal, 1=minimum

tsto tube side tolerance for plate

tstp tube side test pressure

tupr distance tubes project from tubesheet

weir option to eliminate weir in kettle (-1=no weir)

carbon steel material normalized/tempered:

heat
0=no, 1=yes
 Shell&TubeMech: Change Codes - Cylinders &
Covers
These are the cylinders and covers change codes that are available in the
Shell&TubeMech program:

Front Rear
Head Head

cover
cover cyl
cyl

fcot= rcot=
thickness
fcyt= rcyt=

outside fcod= rcyd=

diameter fcyd= rcod=

length (+) fcyl= rcyl=

ext.press.length eln2= eln3=

ellip head ratio fcer= rcer=

toris head dish

fcdr= rcdr=
r.*

toris head k.
fckr= rckr=
rad.*

over "hub"
fhlg= rhlg=
length

Shell Shell Cover

cyl cyl cover

thickness shth= scyt= scot=

outside
scyd= sccd= scod=
diameter

length (+) scyl= sccl=

ext.press.length
eln2= eln4=
(&)

ellip head ratio scer=

toris head dish

scdr=
r.*

toris head k.
sckr=
rad.*

cover "hub"
sclg=
length
(+)=flange/ts face-to-face or weld
*=in percent of head diameter.
(&)=eln1 and stf1 should be issued together stf1=number of stiff.rings

Eccentric Distr Belt Distr Belt

Vapor
Kettle A B

Ann. Ann.
Redcr Cyl Belt Cyl Cyl
Ring Ring

thickness erth= keth= vbth= — — — —

outside
— keod= vbod= — — — —
dia

material ermt= kemt= — — — — —

id/length — keid/kcyl — — — — —
 Shell&TubeMech: Nozzles Change Codes
These are the nozzles change codes that are available in the Shell&TubeMech
program.
Note that nozzle NZ*A items are for the first nozzle listed in the input, NZ*B
changes are for the second nozzle, etc.

Nozzle Nozzle Dome

Reinf Reinf
Cyl Redcr Cyl
Pad Pad

nzta- ncta- nrta-

thickness zrta-j nnta-j
j j j

outside zrda- nrda-

— — —
dia j j

parallel nzpa-
— — — —
limit j

Code Description

nzxa thru distance nozzle extends beyond inner surface of

nzxj vessel

fnfa thru Aspen EDR facing type for nozzle flange (ASME
fnfj 2-5-2) (value=1 to 9)

wnfa thru width of nubbin for nozzle flange (ASME table 2-

wnfj 5-2)

increase nozzle to vessel weld leg to eliminate

nwld
pad: 0=yes, 1=no

percent parallel limit for shell nozzle adjacent to

nplm
tubesheet (0=100%)

clearance between tube nozzle flange and back

nfct
side of flange (0=0.5")

provide 100% metal replacement in pad:

nrtp
0=no, 1=uncorroded, 2=corroded

rpmt minimum reinforcing pad thickness

clearance between reinf. pad weld and back of

nrcl
flange/tubesheet (0=2")

clearance between nozzle cyl. weld and back of

nccl
flange/tubesheet (0=2")

clearance between shell nozzle flange & front side

nfcs
of tubesheet (0=0.5")
 Shell&TubeMech: Body Flanges Change Codes
These are the body flanges change codes that are available in the
Shell&TubeMech program:

Front Head Rear Head

at at
Cover Cover
TbSh TbSh

thickness ffct= fftt= rftt= rfct=

min bolt
fcmb= ftmb= rtmb= rcmb=
dia

facing
fbfa= fbfb= fbff= fbfg=
type

nubbin
wbfa= wbfb= wbff= wbfg=
width

confined
fccj= ftcj= rtcj= rccj=
joint(**)

gasket
gawa= gawb= gawf= gawg=
width

weld
fwla= fwlb= fwlf= fwlg=
height

Shell

Front Rear Cover

thickness fsft= rsft= scft=

min bolt dia — — scmb=

facing type fbfc= fbfd fbfe=

nubbin
wbfc= wbfd= wbfe=
width

confined
fscj= —- sccj=
joint(**)

gasket
gawc= gawd= gawe=
width

weld height fwlc= fwld= fwle=

**=(0=no, 1=yes)
fbft= front backing ring flange thickness
rbft= rear backing ring flange thickness
bolt= bolt type: 1=u.s., 2=metric
shnk= DIN bolt type: 1=waisted-shank, 2=rigid
sfdt= design temperature for shell side body flanges and bolting
tfdt= design temperature for tube side body flanges and bolting
 Shell&TubeMech: Change Codes - Floating Head
Flange
These are the floating head flange change codes that are available in the
Shell&TubeMech program:

Code Description

floating head - flange thickness (recess not

fhft
included)

fhid floating head - flange inside diameter

fhdi floating head - dish inside crown radius

fhdt floating head - dish (or head) thickness

floating head - dish lever arm(+ toward tube

fhhr
side/- toward shell side)

fhmb floating head - minimum bolt outside diameter

floating head - backing ring flange thickness

fhbf
(recess not included)

floating head - corrosion on the shell side of

cifh
floating cover

fhtd floating head - design temperature

confined joint for rear head gasket at tubesheet:

rtcj
0=no, 1=yes

bjac facing type for inside flt. head flange (ASME

fhnu
2-5-2) (value=1 to 9)

width of nubbin for inside float. head flange

fhwi
(ASME table 2-5-2)

FHFL or floating head - flange rating (FHFL or BFLF=1 for

BFLF rating)

IFH "S" type backing ring recess:

BRRE
0=program, 1=none, 2=std., 3=angled
 Shell&TubeMech: Tubesheets & Expansion Joint
Change Codes
These are the tubesheets and expansion joint change codes that are available
in the Shell&TubeMech program:

Code Description

conv number of convolutions

minimum expansion joint cycle life (TEMA

cycl
default=2000 cycles)

diff differential design pressure: 0=no, 1=yes

difp actual diff. pressure

ejbe bellows: 1=unreinforced, 2=reinforced

ejca expansion joint corrosion all

expansion joint straight flange - inner cylinder

ejfa
(TEMA fig. rcb-8.21) **

expansion joint straight flange - outer cylinder

ejfb
(TEMA fig. rcb-8.21) **

ejod expansion joint outside diameter

expansion joint knuckle radius at inside junction

ejra
(TEMA fig. rcb-8.21)

expansion joint knuckle radius at outside

ejrb
junction (TEMA fig. rcb-8.21)

ejrm bellows reinforcement material

expansion joint thickness (TEMA "te" fig. rcb-

ejth
8.21)

expansion joint type: 91=f*f 92=flanged only

ejtp
93=bellows

expansion joint width (TEMA 2*"lo" fig. rcb-

ejwi
8.21) **

fixed tubesheet attachment: 1=backing strip,

ftsa
2=land, 3=stub

ftsc front tubesheet clad thickness

** if -1 is entered, value will be zero in calculations

ftst front tubesheet thickness

expansion joint outer cylinder thickness (TEMA

octh
"to" fig. RCB-8.21)

rtsc rear tubesheet clad thickness

rtst rear tubesheet thickness

fixed tubesheet standard selection: 0=program

tsco
1=ASME 2=TEMA

xjsr expansion joint spring rate - new

xsrc expansion joint spring rate - corroded

** = if -1 is entered, value will be zero in calculations.

 Shell&TubeMech: Change Codes - Supports
These are the supports change codes that are available in the
Shell&TubeMech program:

Code Description

saddle-to-shell angle of contact (100 to 170

deg)
angc
increasing angc will reduce all stresses except
bending at midspan

satw saddle transverse width - reciprocal of angc

distance from face of front tubesheet to first

stda
saddle (a)

distance from face of front tubesheet to second

saddle (b)
placing saddle closer to respective tubesheet
stdb will decrease bending stress at saddle but
increase both bending at midspan and shell
tangential shear (unstiffened by head or
flange/tubesheet)

salw saddle longitudinal width

wear plate thickness (saddles and lugs) -1 = no

plate
increasing both salw or wptk will reduce both
circumferential stress at horn of saddle and ring
wptk
compression over saddle
if the saddle is located further than a/r=0.5 the
vessel thk. Will not include the wear plate in the
calculation of the circum.stress

lugt vertical lug thickness (base plate and gussets)

lugh vertical lug height

 Shell&TubeMech: Dimensions Change Code
These are the dimensions change codes that are available in the
Shell&TubeMech program:

Code Description

elevation of nozzles from the centerline of the

nzel
vessel

nzla thru
nozzle elevation from the centerline of the vessel
nzlj

stla thru
support elevation from centerline of vessel
stld

nzda thru distance of nozzle center from front face of

nzdj front tubesheet

xjda thru distance of expansion joint from front face of

xjdc front tubesheet

stda thru distance of support from front face of front

stdd tubesheet

cpda thru distance of coupling from front face of front

cpdj tubesheet

drawing reference point. 0,1=face of front TS

rfpt
2=centerline front head nozzle
 Shell&TubeMech: Results
The reported Results are divided into six sections:
Input Summary
Design Summary
Vessel Dimensions
Price
Drawings
Code Calculations
 Shell&TubeMech: Input Summary
The Input Summary contains three sections:
Basic Data/ Fittings/Flanges
Cylinders/Covers/Tubesheets
Materials/Lift Lugs/Partitions
 Shell&TubeMech: Basic Data/Fittings/Flanges
This part of the input file summary includes information on:
Description/Codes and Standards
Design Specifications
Geometry
Tubesheet/Tubes
Baffles/Tube Layout
Supports -Horizontal/Vertical
Nozzles
Nozzle Cyl/Re-pads
Flanges
Flange Misc.
 Shell&TubeMech: Cylinders/Covers/Tubesheets
Details
This part of the input file summary provides the detailed input information
on:
Cylinders
Front Head Details
Rear Head Details
Front Head Cover
Front Head Cover Details
Rear Head Cover
Rear Head Cover Details
Shell Cylinder
Tubesheets Details
Expansion Joint Details
Shell Cover
 Shell&TubeMech: Materials/Lift Lugs/Partitions
This part of the input file summary includes information on:
Main Materials
Nozzle Global Materials
Nozzle Specific Materials
Domes/Coupling Materials
Lift Lug Details
Pass Partitions
Tie Rods and Spacers
Nozzle Clearances
 Shell&TubeMech: Design Summary
The Design Summary contains five sections:
Warnings & Messages
Design Specifications/Materials
Overall Dimensions/Fitting Locations
MDMT/MAWP/Test Pressure
 Shell&TubeMech: Warnings & Messages
Aspen EDR provides an extensive system of warnings and messages to help
the designer of heat exchanger design. Messages are divided into five types.
There are several hundred messages built into the program. Those messages
requiring further explanation are described here.
Warning Messages: These are conditions, which may be problems, however
the program will continue.
Error Messages: Conditions which do not allow the program to continue.
Limit Messages: Conditions which go beyond the scope of the program.
Notes: Special conditions which you should be aware of.
Suggestions: Recommendations on how to improve the design.
 Shell&TubeMech: Design Specifications
This is intended to be a concise summary of the design requirements,
including calculated design information such as weights and nozzle flange
ratings. The codes in effect are clearly shown indicating applicable date of
issue.
See Also
Materials of Construction
 Shell&TubeMech: Materials of Construction
Provides a summary of materials used in the design for all major components.
For example:

Component Material Name

Shell Cylinder SA-516 Gr 70 Steel Plt

Front Head Cylinder SA-516 Gr 70 Steel Plt

Rear Head Cylinder SA-516 Gr 70 Steel Plt

Front Head Cover SA-516 Gr 70 Steel Plt

Rear Head Cover SA-516 Gr 70 Steel Plt

Front Tubesheet SA-516 Gr 70 Steel Plt

Rear Tubesheet SA-516 Gr 70 Steel Plt

Front Head Flange

SA-516 Gr 70 Steel Plt
At TS

Rear Head Flange At

SA-516 Gr 70 Steel Plt
TS

Front Head Flange

SA-516 Gr 70 Steel Plt
At Cov

Front Head Gasket Flt Metal Jkt Asbestos Soft

At TS Steel

Rear Head Gasket Flt Metal Jkt Asbestos Soft

At TS Steel

Front Head Gasket Flt Metal Jkt Asbestos Soft

At Cov Steel

Tubes SA-214 Wld C Steel Tube

Baffles SA-285 Gr C Steel Plt

Tie Rods SA-36 Bar

Spacers SA-214 Wld C Steel Tube

Shell Support A SA-285 Gr C Steel Plt

Shell Support B SA-285 Gr C Steel Plt

Nozzle A SA-106 Gr B Sml Steel Pipe

Nozzle B SA-106 Gr B Sml Steel Pipe

Nozzle C SA-106 Gr B Sml Steel Pipe

Nozzle D SA-106 Gr B Sml Steel Pipe

Nozzle Flange A SA-105 Carbon Steel Forg

Nozzle Flange B SA-105 Carbon Steel Forg

Nozzle Flange C SA-105 Carbon Steel Forg

Nozzle Flange D SA-105 Carbon Steel Forg

Nozzle
SA-516 Gr 70 Steel Plt
Reinforcement A

Nozzle
SA-516 Gr 70 Steel Plt
Reinforcement B

Nozzle
SA-516 Gr 70 Steel Plt
Reinforcement C

Nozzle
SA-516 Gr 70 Steel Plt
Reinforcement D

Front Hd Bolting At
SA-193 B7 Steel Blt
TS

Rear Hd Bolting At
SA-193 B7 Steel Blt
TS

Front Hd Bolting At
SA-193 B7 Steel Blt
Cov

Expansion Joint SA-516 Gr 70 Steel Plt

Nozzle Flange
SA-193 B7 Steel Blt
Bolting A

Nozzle Flange
SA-193 B7 Steel Blt
Bolting B

Nozzle Flange
SA-193 B7 Steel Blt
Bolting C

Nozzle Flange
SA-193 B7 Steel Blt
Bolting D

Flt Metal Jkt Asbestos Soft

Nozzle Flg Gasket A
Steel

Flt Metal Jkt Asbestos Soft

Nozzle Flg Gasket B
Steel

Flt Metal Jkt Asbestos Soft

Nozzle Flg Gasket C
Steel

Flt Metal Jkt Asbestos Soft

Nozzle Flg Gasket D
Steel

Shell Side Nozzle

SA-105 C Steel Coupl
Cplgs

Tube Side Nozzle

SA-105 C Steel Coupl
Cplgs
 Shell&TubeMech: Overall Dimensions
Overall dimensions are calculated as well as intermediate component lengths.
These dimensions will also be shown on some of the Shell&TubeMech
drawings, such as the setting plan and sectional drawing.
The dimensions shown are:
Overall front head assembly
Front Tubesheet
Tubesheet thickness
Tube side recess
Shell side recess
Welding stub end(s)
Cladding Thickness
Shell
Rear Tubesheet
Tubesheet thickness
Tube side recess
Shell side recess
Welding stub end(s)
Cladding Thickness
Overall rear head assembly
Overall shell cover assembly
Unit overall length
 Shell&TubeMech: Fitting Locations
All fittings are located from two reference points: distance from the front
tubesheet and distance from the front head nozzle. These dimensions will also
appear on Aspen Shell&TubeMech setting plan drawings.
If any nozzles are offset from the vessel centerline, the amount of the offset
will also be indicated.
 Shell&TubeMech: Center of Gravity
A general center of gravity is calculated based on each component weight.
This reference point can be used when preparing for vessel installation and
for proper anchoring during movement.
 Shell&TubeMech: MDMT
Minimum Design Metal Temperatures are set based upon the lowest operating
temperature the pressure vessel will encounter. Material specifications,
impacting testing, and PWHT should be selected that will meet the MDMT
requirements per the applicable design construction code.
See Also
Controlling Component
 Shell&TubeMech: Controlling Component
The program will examine each component separately and calculate its
minimum design metal temperature without having to impact test the
material. An "*" indicates the controlling component (the one with the highest
temperature).
By changing material specifications or testing the component the user can
lower the minimum design metal temperature to a desired value.
The ASME Code has many rules on this subject (such as those presented in
UG-20(f)) so it is recommended to use additional judgment and experience
when deciding on the minimum design metal temperature for a vessel.
 Shell&TubeMech: MAWP
The Maximum Allowable Working Pressure is the maximum pressure that the
vessel may encounter and not have any component's pressure stress exceed
the allowable design stress value per applicable design code.
See Also
Controlling Component
 Shell&TubeMech: Controlling Component
The program will calculate the maximum allowable working pressure (MAWP)
for each component of the vessel. The one with the lowest pressure will be
selected as the controlling component and marked with a "*" for the shell side
and a "+" for the tube side.
Two sets of pressures are selected:
One for design conditions (corroded at design temperature)
One for "new and cold" conditions (uncorroded at ambient temperature)
If you want to redesign the equipment using the MAWP, you should change
the input data to rating mode. In some cases when the tubesheet controls the
MAWP, it will not be possible to design the equipment using the MAWP,
because the tubesheet calculation may yield a new MAWP. This occurs
because the program uses the ASME design method, which is dependent not
only on the tubesheet geometry but also on the shell and channel geometries
as well as different operating cases, such as thermal stresses only, pressure
and thermal stresses concurrently, etc. As the design pressure changes, other
parameters may control the overall MAWP resulting in a different number.
 Shell&TubeMech: Test Pressure
The program per the applicable design construction code calculates test
pressures for the unit.
 Shell&TubeMech: PWHT
Post weld heat treatment is performed if required by the applicable design
code or as specified by the user in the input.
 Shell&TubeMech: Vessel Dimensions
The Vessel Dimensions Section is subdivided into six sections:
Cylinders & Covers
Nozzles/Nozzle Flanges
Flanges
Tubesheets/Tube Details
Expansion Joint
Supports/Lift Lugs/Wind & Seismic Loads
 Shell&TubeMech: Cylinders & Covers
This section reports the following calculated design dimensions:
Thickness
Cylinders and covers are shown with actual thicknesses selected as well as
calculated minimum required thicknesses for both internal as well as external
pressure. If a TEMA standard was selected, the program also displays the
minimum TEMA thickness based on materials of construction, the TEMA class
and the vessel diameter.
Radiography
Code rules are followed for the three typical radiography options: no
radiography, spot and full. The program displays the value for the joint
efficiency used in the design formulas. In many cases, the program
automatically increases the radiography required based on the component
calculated thickness per applicable code rules.
External Pressure
The external pressure summary provides limits of design for pressure,
thickness and length. You can clearly identify which standard controls the
actual thickness selected. If reinforcement rings are required for the shell
cylinder, the maximum length is shown for ring placement.
Kettle Cylinder/Distributor Belt Thickness
Cylinders and covers are shown with actual thicknesses selected as well as
calculated minimum required thicknesses for both internal as well as external
pressure. If a TEMA standard was selected, the program also displays the
minimum TEMA thickness based on materials of construction, the TEMA class
and the vessel diameter.
Kettle Cylinder/Distributor Belt Radiography
Code rules are followed for the three typical radiography options: no
radiography, spot and full. The program displays the value for the joint
efficiency used in the design formulas. In many cases, the program
automatically increases the radiography required based on the component
calculated thickness per applicable code rules.
Kettle Cylinder/Distributor Belt External Pressure
The external pressure summary provides limits of design for pressure,
thickness and length. You can clearly identify which standard controls the
actual thickness selected. If reinforcement rings are required for the shell
cylinder, the maximum length is shown for ring placement.
 Shell&TubeMech: Nozzles/Nozzle Flanges
This section reports the following calculated design dimensions:
Nozzles
Cylinder and nozzle reinforcement calculation results are summarized.
Nozzles are shown one per column identifying the side where the opening is
located (shell or tube side) as well as the outside diameter and corresponding
thicknesses.
Reinforcement
The neck cylinder wall thickness is determined following the code rules. The
reinforcement requirements follow, depending on the availability of metal
around the opening including excess vessel and nozzle neck wall thickness
and welds. If a reinforcing pad is necessary, the program will select one. The
program optimizes the reinforcement calculation by first trying to avoid the
use of a pad by increasing the nozzle weld size and then by selecting the
thinnest possible pad that complies with the code. You can change all nozzle
and reinforcement dimensions. For example, you can eliminate a pad by
increasing the nozzle neck thickness.
Nozzle Flanges
Nozzle flanges can be calculated or selected from standards (for example
ANSI B16.5). The program determines which flange is acceptable based on
materials of construction and design pressure and temperature. Typical ANSI
classes are 150, 300, 600, 900 and 1500 in a variety of shapes (slip-on, lap
joint, weld necks). The program defaults to an ANSI slip-on (SO) flange type.
Domes
Cylinder and nozzle reinforcement calculation results are summarized. Nozzle
domes are shown one per column identifying the side where the opening is
located (shell or tube side) as well as the outside diameter and corresponding
thicknesses.
Reinforcement
The dome cylinder wall thickness is determined following the code rules. The
reinforcement requirements follow, depending on the availability of metal
around the opening including excess vessel and dome cylinder wall thickness
and welds. If a reinforcing pad is necessary, the program will select one. The
program optimizes the reinforcement calculation by first trying to avoid the
use of a pad by increasing the dome weld size and then by selecting the
thinnest possible pad that complies with the code. You can change all nozzle
and reinforcement dimensions. For example, you can eliminate a pad by
increasing the dome cylinder thickness.
 Shell&TubeMech: Flanges
This section reports these calculated design dimensions:
Body flange design
You can easily review all the major flange dimensions for all flanges (outside
diameter, bolt circle, bolt diameter and number, etc.). The results will show
optimized body flanges designs per the applicable code rules. Designed
flanges follow the rules dictated by the specified code. As in the case of nozzle
flanges, typical flange types available are ring, lap joint and hub type. The
program results will identify which optional type flange calculation method
was used, loose or integral.
Backing flange design
Results for any applicable backing flanges will be provided, such as for S type
rear heads and for fixed tubesheets designs with removable heads were
tubesheets where not extended for bolting.
 Shell&TubeMech: Tubesheets/Tube Details
This section reports these calculated design dimensions:
Tubesheets
The tubesheet results always show both the TEMA method and the code
results no matter which method was selected in the input (you can select
TEMA, Code, or the thicker/thinner of the two methods for the tube sheet
design). If no method is selected, the program uses the thicker tubesheet of
the two methods.
The program then uses the thickness based upon what calculation option that
you selected. Note that if the shell and/or head are welded to the tubesheet
with the ASME method, the program may be able to better optimize to a
thinner tubesheet thickness if you vary the attaching cylinder thicknesses.
Tube details
A summary of tube details is provided. The number of tubes and the outer
tube limit are either those specified in the input, in which case the program
checks their validity, or those calculated by the program.
Double Tubesheets
The standard results are based upon the TEMA methods for double tubesheet
design. If you have selected to use the ASME tubesheet design methods and
have also specified double tubesheets, the program uses ASME to estimate
the individual tubesheet thicknesses and then apply TEMA for the gap
requirements.
Bundle Removal Space
The amount of space required to remove the tube bundle for servicing (not
applicable for fixed tubesheet type exchangers). Space excludes the front
head length if head is removable, bolted to the front of the tubesheet.
See Also
Tubesheet Calculation Methods
Tubesheet/Cylinder Optimization
 Shell&TubeMech: Tubesheet Calculation
Methods
Tubesheets are designed to the applicable design construction code
requirements. For example the program uses two major methods to design
tubesheets to USA standards: TEMA and ASME Section VIII Division 1
Appendix AA.
The program defaults to the thicker tubesheet result from each method.
However, you can select to a specific design method. Depending on many
factors, such as diameter, materials, pressures, temperatures, geometry, etc.,
either method could result in the thinner tubesheet.
In the case of fixed tubesheet units, the program will calculate an expansion
joint if required or requested in the input.
 Shell&TubeMech: Expansion Joint
A summary of the results of the TEMA calculations for a flanged and flued
type expansion joint or the results of the ASME bellows type joint or other
applicable design code will be provided.
 Shell&TubeMech: Supports / Lift Lugs / Wind &
Seismic Loads
This section reports these calculated design dimensions:
Supports
Lift lugs
Wind and Seismic overturning moments
See Also
Horizontal Supports
 Shell&TubeMech: Horizontal Supports
The method used was originally developed by L.P. Zick.
The program alerts the user if any of the allowable stresses are exceeded. If
that occurs several methods are available to alleviate the overstressed
condition.
To alleviate an overstressed condition in horizontal units, the user can place
the saddles closer to respective tubesheets/flanges (to decrease the bending
at the saddle but increase both bending at midspan and shell tangential
shear). Increasing the width of the saddle or adding a wear plate will reduce
both circumferential stress at the horn of the saddle and ring compression
over the saddle. Increasing the saddle-to-shell angle of contact will also
reduce all stresses except bending at midspan.
 Shell&TubeMech: Price
The Price Section reports the following information:
Item Description

A summary of the detailed costing

Cost showing material cost, total labor, and
estimate mark ups on material and labor are
provided.

Material, labor, mark up, and total

Cost
selling cost are provided for the
summaries
exchanger.

Material & Material and labor will be provided for

Labor each major component of the heat
details exchanger.

Final Final assembly labor and material are

assembly summarized.

A complete bill of materials is provided

listing all components. A rough
Bill of dimensions listing for material
Materials purchase is provided as well as a
finished dimensions bill of material for
manufacturing.

A complete labor per component and

Labor
operation are provided for section and
details
assemblies.
 Shell&TubeMech: Drawings
The Drawings Section is subdivided into three sections:
Setting Plan Drawing
A setting plan drawing is provided showing location of nozzle, supports, and
overall dimensions.
Tubesheet Layout Drawing
A scale tube layout is provided showing tube, tie rod, and baffle cut locations.
All Drawings: Fabrication Drawings
Shell&TubeMech provides a complete set of fabrication drawings showing all
components for construction. Drawings are to scale.
 Shell&TubeMech: Code Calculations
Shell&TubeMech provides a complete calculation details section showing all
Code methods and variables to verify the design to the applicable Code.
Calculations are provided for:
Cylinders/Cover
Body Flanges
Tubesheets/Expansion Joints
Nozzles
Supports
Wind/Seismic Loads
Lifting Lugs
MAWP/MDMT/Test Pressures
 AirCooled: Thermal Design of Air Cooled Heat
Exchangers

AirCooled Input
AirCooled Results

AirCooled Getting Started Guide

Crossflow Heat Exchangers

Quick Guide to Geometry Selection

Optimization of Design
 AirCooled: Input
Problem Definition
Headings/Remarks
Application Options
Process Data

Physical Property Data

Stream Composition
Stream Properties

Exchanger Geometry
Geometry Summary
Unit Geometry
Tubes
Bundle
Headers & Nozzles
Fans
Structures/Walkways

Construction Specifications
Materials of Construction
Design Specifications

Program Options
Design Options
Thermal Analysis
Methods/Correlations
Outside Distribution
 AirCooled: Problem Definition

The Problem Definition section includes the following screens:

Headings/Remarks
Application Options
Process Data
 AirCooled: Headings/Remarks
The Headings/Remarks section includes the following screens:
API Specification Sheet Descriptions
 AirCooled: Application Options
The Application Options section includes the following screens:
Application Options
 AirCooled: Process Data
The Process Data section includes the following screens:
Tube Side Stream
Outside Stream
Tube Side Fouling
Outside Fouling
 AirCooled: Exchanger Geometry
The Exchanger Geometry section includes the following screens:
Geometry Summary
Unit Geometry
Tubes
Bundle
Headers & Nozzles
Fans
Structures/Walkways
 AirCooled: Geometry Summary
The Geometry Summary section includes the following screens:
Geometry
Tube Layout
 AirCooled: Unit Geometry
The Unit Geometry section includes the following screens:
Unit Geometry
Accessories
Clearances
 AirCooled: Tubes
The Tubes section includes the following screens:
General
Serrations/Studs
 AirCooled: Bundle
The Bundle section includes the following screens:
Bundle
 AirCooled: Headers & Nozzles
The Headers & Nozzles section includes the following screens:
Headers
Nozzles
 AirCooled: Fans
The Fans section includes the following screens:
Fan
Fan Curves
Fan/Plenum Construction
Fan Motors
 AirCooled: Structures/Walkways
The Structure/Walkway section includes the following screens:
Support Structure
Walkways
 AirCooled: Constructional Specifications
The Constructional Specifications section includes the following screens:
Materials of Construction
Design Specifications
 AirCooled: Materials of Construction
The Materials of Construction section includes the following screens:
General
 AirCooled: Design Specifications
The Design Specifications screen includes the following inputs:
Codes and Standards
Design Code
Code stamp
Material standard
Dimensional standard

Design Conditions
Design pressure
Vacuum design pressure
Test pressure
Design temperature
Corrosion allowance
 AirCooled: Program Options
The Program Options section includes the following screens:
Design Options
Thermal Analysis
Methods/Correlations
Outside Distribution
 AirCooled: Design Options
The Design Options section includes the following screens:
Geometry Limits
Process Limits
Optimization Options
 AirCooled: Thermal Analysis
The Thermal Analysis section includes the following screens:
Process
Calculation Options
 AirCooled: Methods/Correlations
The Methods/Correlations section includes the following screens:
Tube Side
Outside
Tube Side Enhancement
Outside Enhancement
 AirCooled: Outside Distribution
The Outside Distribution section includes the following screens:
Inlet Distribution
Flow
Temperature
 AirCooled: Results
Input Summary
Input Summary

Result Summary
Warnings & Messages
Optimization Path
Recap of Designs
API Sheet
Overall Summary

Thermal / Hydraulic Summary

Performance
Heat Transfer
Pressure Drop

Mechanical Summary
Exchanger Data
Setting Plan / Tubesheet Layout
Cost / Weights

Calculation Details
Interval Analysis - Outside Tubes
Interval Analysis - Tube Side
 AirCooled: Input Summary
This section provides you with a summary of the information specified in the
input file. It is recommended that you request the input data as part of your
printed output so that it is easy to reconstruct the input, which led to the
design.
 AirCooled: Result Summary
The Result Summary section includes the following screens:
Warnings & Messages
Optimization Path
Recap of Designs
API Sheet
Overall Summary
 AirCooled: Warnings & Messages
Aspen AirCooled provides an extensive system of errors, warnings and other
messages to help you use the program. They are for the most part self
explanatory, and contain information on the values of parameters which have
led to the reported condition. There are several hundred messages built into
the program, and these can be divided into number of types
Range Checking Warning
These relate to input values which are outside the range of what is normally
expected. You should check that the input value referred to is correct. If so
the message can usually be ignored, although for unusual exchanger
geometries, or unusual fluid properties, it is likely that the uncertainty in the
results is exacerbated.
Input Omission Error
These identify input parameters which are necessary for the program to run.
Whether a particular parameter is necessary can depend on the values of
other parameters. Required input is normally identified in the User interface,
although there are occasionally instances where a required item is not
highlighted in the Interface, or where an item is shown as required by the
interface, does not lead to an error when the program is run.
Range Checking Error
These identify input values which are beyond the range of what is permitted.
They cause program execution to cease.
Results Warning
The run has completed, but problems have been identified with some part of
the calculation, which indicate that some aspect of the results may be subject
to more uncertainty than normal.
Results Error
The run has either failed to generate a significant part of the results, or failed
to complete in some way that many of the results given should not be relied
on..
Operation Warning
The run has completed, but is predicting operation which does not meet
normal practice, or is in some other way inadvisable, or in extreme cases
impracticable.
Advisory
There is some feature of the exchanger, or its operation which is unusual, and
for which better alternatives may exist
Notes
Any other information which may be useful
 AirCooled: Optimization Path
This part of the output is the window into the logic of the program. It shows
some of the heat exchangers the program has evaluated in trying to find one,
which satisfies your design conditions. These intermediate designs can also
point out the constraints that are controlling the design and point out what
parameters you could change to further optimize the design.
To help you see which constraints are controlling the design, the conditions
that do not satisfy your specifications are noted with an asterisk (*) next to
the value. The asterisk will appear next to the required tube length if the
exchanger is undersurfaced, or next to a pressure drop if it exceeds the
maximum allowable.
 AirCooled: Recap of Designs
The recap of design cases summarizes the basic geometry and performance of
all designs reviewed up to that point. The side by side comparison allows you
to determine the effects of various design changes and to select the best
exchanger for the application. As a default, the recap provides you with the
same summary information that is shown in the Optimization Path. You can
customize what information is shown in the Recap by selecting the Customize
button. You can recall an earlier design case by selecting the design case you
want from the Recap list and then select the Select Case button. The program
will then regenerate the design results for the selected case.
 AirCooled: API Sheet
The API sheet displays the results from the thermal calculations using the
standard datasheet detailed in the API standard.
 AirCooled: Overall Summary
The Overall Summary provides a concise summary of the inlet/outlet process
conditions of each stream as well as important criteria regarding, heat
transfer, pressure drop, velocities, temperature differences and heat loads.
This information can be used to quickly evaluate the overall performance of
the unit. A basic summary of the exchanger’s geometric configuration is also
provided so that other geometry options can be considered during the
analysis of the overall performance data.
 AirCooled: Thermal / Hydraulic Summary
The Thermal / Hydraulic Summary section includes the following screens:
Performance
Heat Transfer
Pressure Drop
 AirCooled: Performance
The Performance section includes the following screens:
Overall Performance
Resistance Distribution
Tube Side Composition
 AirCooled: Heat Transfer
The Heat Transfer section includes the following screens:
Heat Transfer Coefficients
Duty Distribution
Tube Wall Temperature
 AirCooled: Pressure Drop
The Pressure Drop section includes the following screens:
Tube Side
Outside
 AirCooled: Mechanical Summary
The Mechanical Summary section includes the following screens:
Exchanger Data
Setting Plan / Tube Layout
Cost / Weights
 AirCooled: Exchanger Data
The screens within the Exchanger Data section summarize the data associated
with the following:
General Unit & Bundle
Fan Details
Tubes & Fins
Nozzles & Headers
Weights & Volumes
hiTRAN Inserts
 AirCooled: Setting Plan / Tube Layout
The Setting Plan / Tube Layout section includes the following screens:
Setting Plan
Tube Layout
 AirCooled: Cost / Weights
A summary of the costs and the weights of the major components are listed.
 AirCooled: Calculation Details
The Calculation Details section includes the following screens:
Interval Analysis - Outside Tubes
Interval Analysis - Tube Side
 AirCooled: Interval Analysis - Outside Tubes
The Interval Analysis – Outside Tubes section includes the following screens:
Interval Analysis
Physical Properties
Plots
 AirCooled: Interval Analysis - Tube Side
The Interval Analysis – Tube Side section includes the following screens:
Interval Analysis
Physical Properties
Pressure Change
Plots
 Overview

The purpose of this exercise is to determine if there is sufficient area

available to cool a process fluid to the required temperature for a forced-
draught air-cooled heat exchanger using Aspen Air Cooled Exchanger
(AirCooled).

Contents:
Overview
Process Overview
Geometry Overview
Building the Simulation
Running the File
Viewing the Results
Additional Exercise

Next step:
Process Overview
 Process Overview

Details of the process data as well as the geometry are given in the tables
below.

SI Units

Process Side X-side

Water Dry Air

Flow rate 30500 177500 kg/h

Temperature In/Out 92 / 56 37 / C

Inlet Pressure 1.2 Atmosphere bar (abs/gauge)

Estimated pressure
0.18 bar
drop

Fouling Resistance 0.00002 m2K/W

British Units

Process Side X-side

Water Dry Air

Flow rate 67241 391320 lb/h

Temperature In/Out 197.6 / 132.8 98.6 / F

Inlet Pressure 17.4 Atmos. psia/psi

Estimated pressure
2.61 psi
drop

Fouling Resistance 0.00011357 h ft2 F/Btu

Next step:
Geometry Overview
 Geometry Overview

SI British

Header:

Number of inlet nozzles 4 4

Inlet nozzle inside

101.2 mm 4 inches
diameter

Number of outlet nozzles 4 4

Outlet nozzle inside

101.2 mm 4 inches
diameter

Type of Header Box Box

Bundle:

Number of passes 4 4

Number of rows 4 4

Number of tubes 160 160

Type of bundle:
Staggered – evens row to
left

Tube:

Effective length of tube 6020 mm 237 inches

Traverse pitch 58.4 mm 2.3 inches

Tube Inner diameter 21.32 mm 0.839 inches

Tube Outer diameter 25.4 mm 1 inches

Layout angle 30 Degree 30 Degree

Fins:

G fin

Frequency 433 /m 11 /inches

Tip diameter 57.16 mm 2.25 inches

Mean fin thickness 0.457 mm 0.018 inches

Next step:
Building the Simulation
 Building the Simulation

Launch Aspen Exchanger Design & Rating (EDR) from either the shortcut
(Start | All Programs | AspenTech | Exchanger Design and Rating | Exchanger
Design and Rating User Interface or the AspenOne Tool bar. Select Aspen Air
Cooled Exchanger (AirCooled) from the New tab and click OK.

AirCooled will open where the screen as shown below will be displayed.
To change the units which data can be entered into the program there are a
number of options;
Click on the drop down arrow for the “Units of Measure” and select SI units
From the menu bar, select Tools, then Program Settings. From the General
tab set SI as the Default set of the units of measure. Click OK, where the next
time AirCooled is started, SI units will be the default set of units.
Highlight the Application Option from the tree menu structure on the left-
hand side and set the AirCooled program calculation mode as
“Rating/Checking”
Press the Next button to navigate to the next form where input data is
required or highlight Process Data from the navigation tree. Enter the process
data for the Process side in the Tube Side Stream tab as given in the process
overview table previously.
The flowrate data has been specified as kg/h whereas the input screen by
default shows kg/s. Therefore click on the scroll down arrow by the mass
flowrate units and select kg/h then enter the data.
When sufficient data has been entered necessary for the program to run, the
red cross will disappear from the menu tree.
(NOTE: Numbers in red are program defaults and are not entered by the
user)
Select the Outside Stream tab and enter the process data for the X-side.
Again be careful with the selection of the units.
The Property Data can now be entered, where only the tube side information
is required as in Application Options the default of Dry Air was used for the
Outside tube application, so the internal properties database will be used and
hence the Outside Compositions and Properties are grayed out.
In the Compositions tab, select COMThermo as the Physical property package.
Click on the Search Databank button, then type in the first few letters of the
fluid required, highlight from the list and click on the Add button to enter in
the selected components list. Click on OK.
In the Composition tab against water enter the weight flowrate or % as 1.
In the Property Method tab, select a Property Package, where in this example
Ideal-Ideal may be selected.
Select Tube Side Properties and then click on the Get Properties button. The
program will now generate physical property data for water between the
temperatures of 56 to 92 C and at the pressure levels of 1.2 and 1.02 bars.
Note: The pressure and temperature ranges have automatically been supplied
by AirCooled.
These can be changed if necessary, by typing new values and then
regenerating the properties.

Now the Exchanger Geometry can be entered. In Exchanger Geometry |

Geometry Summary | Geometry tab enter the tubes and the tube layout
information.

Set to “Use interactive graphical layout to define tube layout”.

Note: The input screen still has a red cross against as the tube length has not
been entered, where the effective length will be supplied later.
Note: The initial layout shown for the pass arrangements can be altered by
selecting the “Tube side to outside flow orientation”. When graphically
specifying the bundle it is advisable to leave this at the default.

In this example, the pass layout will be entered graphically. Select the Tube
Layout tab.
AirCooled has drawn an initial layout based on the number of rows and
passes. However, this layout can be changed if necessary by selecting a Pass
number from the Pass radio button and then right mouse click on a tube to
change the color to that pass. By right mouse clicking on a tube, keeping the
mouse button depressed and then moving to an adjacent tube and releasing
the mouse button, all tubes in-between will be set to the pass. Set the layout
as above where each row contains one pass and pass direction is set such that
the tube side flow is counter current to the X-side.

In Bundle, Bundle tab, set the Effective tube length.

Note: The effective tube length is the total tube length minus any length that
does not contribute to the heat transfer. This includes tubes lengths within
the tubesheets or under tube supports.

Now that the effective length has been supplied there is sufficient information
to estimate the tube length, so the Geometry Summary no longer has a red
check box.

Select Headers & Nozzles and enter the Header type and the number of
nozzles and diameter.
The process data and geometry data have now been entered, but before
running it is best to save the dataset. Select File from the main menu, then
Save As entering the name of the case.

Next step:
Running the file
 Running the File

To run the file either;

From the Main menu select Run | Run AirCooled
Press F5
Click the Run Icon

The Program Status box will appear that can be closed to reveal any Warnings
& Messages. If there are errors then actions should be taken based on the
message.

Next step:
Viewing the Results
 Viewing the Results

The results may be viewed by Results | Thermal / Hydraulic Summary |

Performance and then looking at the Overall Performance and Resistance
Distribution tabs.
The Overall Performance tab shows the temperatures, pressure drops, film
(stream) coefficients and some geometry data. In the Resistance Distribution
tab the area ratio is shown as 1.16. Do not confuse this with the Duty Ratio
for Rating/Checking runs.
The resistance diagram is also shown which gives a diagrammatic
representation of the relative resistances to heat transfer. In order to
increase performance you would normally concentrate on the largest
resistance shown by the position of the tube wall resistance shown in blank.
In this case the largest resistance is outside the tubes.

Next step:
Additional Exercise

Return to:
Overview
 Additional Exercise

As the unit is oversurfaced, it could achieve more duty. To check the duty, in
Input | Problem Definition | Application Options, set the AirCooled program
calculation mode to “simulation” then run the case. The tube side outlet
temperature will be determined as 53.8 C with a duty of 1358kW. This
corresponds to an increase in duty of 1.06 (1358/1280) which is a little less
than that expected from the area ratio in the “Rating/Checking” calculations.

Why is this?

The temperature of the tube side stream with distance can be viewed from
Results | Calculation Details | Interval Analysis – Tube Side in the Interval
Analysis tab. To view this graphically, click in the table of data, then right
mouse click and from the options select “New Plot”. In the Curve tab, for the
Data for X-axis from the scroll down box select “Distance”. For the Data for Y-
axis select “Temperature stream” from the drop down box. Click on the Add
button, where the graph will appear under the selected curves.

Click on the Finish button to view the graph, of the temperature of the 4
passes.
Return to:
Overview
 Crossflow Heat Exchangers Overview
A crossflow heat exchanger has a gas stream flowing over a rectangular bank
of tubes. The gas stream is on the X-side and the process stream is on the
tube side.

Types of crossflow exchangers are:

Air-cooled heat exchangers
Heat recovery banks
Air conditioning units
Superheater & economizers in boiler plant
Inter- and after-coolers

For further information on the various components of an exchanger, and on

the reasons for selecting particular sizes or configurations, please see the
following key topics
Fan Configurations
Pass Arrangements
Nozzle Sizes
Tube Diameter
Tube Wall Thickness
Tube Layout and Tube Pitch
Tube Lengths (Maximum)
Tube Counts
Extended surface types (Plain tubes, high fins, low fins, tube-in-plate, studded
tubes)
Quick Guide to Geometry Selection
 Crossflow Fan Configurations
For an Air-cooled Heat Exchanger, the configuration type will be Forced
Draught or Induced Draught.
Other Crossflow Exchangers such has Heat Recovery Devices where the
exchanger is in a duct are in No Fan configuration. This means that the fan is
elsewhere in the system and not directly connected to the heat exchanger.
An air-cooled heat exchanger in Natural Convection mode (i.e. with fans
switched off) will still be either in Forced or Induced Draught configuration
NOT No Fan configuration.
 Crossflow Pass Arrangements
Crossflow exchangers can have a single tube side pass, but more often have
two or more passes. Multi-pass exchangers almost invariably have an even
number of passes, so that tube side inlet and outlet connections are at the
same end of the exchanger. Sixteen is usually the maximum number of
passes considered in an air-cooled heat exchanger, because of fabrication
problems.
Apart from constructional issues, the basic difference between different pass
arrangements is the magnitude of the temperature driving force for heat
transfer. For a given process inlet temperature and a given approach
temperature on the X-side a pure crossflow unit will give the lowest possible
effective temperature difference. A multi-pass unit with these same inlet
conditions will result in a higher mean temperature difference.
Temperature driving force effects are only important where the tube side
stream changes in temperature. If the tube side is isothermally boiling or
condensing then the temperature driving force is effectively independent of
pass arrangement.
It should be noted that designers frequently adjust the pass geometry to
maximize the heat transfer coefficient on the tube side. This is often practiced
in condensing where the volume of the process liquid decreases through the
unit. In the extreme desuperheating passes may be included which have a
much smaller flow area than the main condensing passes.
 Crossflow Nozzles Sizes
Generally speaking, heat exchanger design engineers will try to keep nozzle
sizes as small as possible to keep down costs. Wherever possible, this means
that making the nozzle the same diameter as the connecting pipework. It
should be remembered, however, that any pressure loss in the nozzle can
often be more effectively used in the tubes and engineers should always
check each run to ensure that pressure drop is not being 'wasted' in a nozzle
when it could be used to increase the number of tube-passes.
Where pressure drop is not a problem, the minimum nozzle size is usually
limited by the maximum allowable fluid velocity. This is a metallurgical
problem since excessive velocities can lead to erosion, especially if the fluid
contains solids in suspension. Clearly, the velocities which can be tolerated
will be much higher for gases than for liquids and it is more helpful to talk in
terms of energy, or density times velocity squared (Rho*V**2) rather than
velocity. On this basis, a safe upper limit for most fluids is around 9000 kg/m
s2 (6000 Ib/ft s2) and tube side nozzles should be sized such that this value
is not exceeded. (Note: THE PROGRAM will size a nozzle to this criterion by
default.)
In air-cooled heat exchangers, transition nozzles may be used. These are
forgings with a standard circular nozzle cross-section at the pipework end and
an elliptical or oval cross section at the header end. This allows headers to be
fabricated with the minimum depth, saving material and fabrication cost of
the key pressure parts of the exchanger. More discussion on headers and
nozzles for air-cooled heat exchanger applications can be found in HTFS
Handbook sheets:
AP16: Single phase pressure loss in a turnaround header;
AP17: Process side pressure loss for single phase loss for single phase flow in
air-cooled heat exchangers;
AM22: Sizing nozzles and headers with single phase flows
In most process heat recovery applications, manifold headers are used,
however, many of the above comments still apply.
 Crossflow Tube Diameter
TEMA section 'C lists nine standard tube outside diameters ranging from 6.35
to 50.8 mm (1/4 to 2 inch). Generally speaking tubes less than 12.7 mm (1/2
inch) are only used for small 'proprietary' type exchangers and tubes greater
than 25.4 mm (1 inch) would only be required for severely pressure drop
limited designs. The standard diameters in general use are, therefore, 12.7,
15.88, 19.05 and 25.4 mm (1/2, 5/8, 3/4 and 1 inch).
The choice of diameter is usually based on established practice rather than
the technical merits of any particular case. Thus 12.7 and 15.88 mm tend to
be specified in smaller exchangers for general industrial use while, in the
Process Industries it is established practice to use 19.05 mm tubes as
standard with 25.4 mm being occasionally used in services where tube side
pressure drop presents a problem.
There are several reasons why 19.05 mm tubes are by far the most
commonly used in the Process Industries:
19.05 mm is the smallest diameter recommended by section 'R' (the section
applicable to petroleum refineries) of the TEMA code
Tubes smaller than 19.05 mm OD tend to have inside diameters, which make
mechanical cleaning difficult
Tube end welding of the smaller tubes is more difficult
The constraint imposed by the initial selection of a standard tube OD leads to
a reduction in the man-hours required for design and cost estimation.
 Crossflow Tube Wall Thickness
The economic choice of tube thickness is the minimum required to withstand
the tube side design pressure.
Rather than calculate this for every single case, design engineers prefer to
use standard minimum values which, for the pressures and temperatures
associated with most exchanger duties, tend to be conservative. TEMA section
'C' gives recommended thicknesses which are more than adequate for most
applications. For high pressures and/or temperature it is necessary to check
whether the selected tube thickness is adequate. TEMA also gives the
maximum allowable internal pressure for tubes at various values of allowable
stress. This last property, which decreases with increasing temperature, can
be obtained from the relevant code. For high pressure on the outside of tubes
there is, unfortunately, no short-cut method for determining the minimum
tube thickness and reference must be made to recognized pressure vessel
code.
When ordering tubes it is necessary to state whether the specified wall
thickness is the average or the minimum required. This distinction is not
usually considered to be significant as far as thermal design is concerned.
When tubes are bent to form U-tubes, the thickness of the tube in the region
of the bend is reduced and it might be necessary, especially at higher
pressures and temperatures, to use tubes that are thicker than normal,
particularly for the inner U-bends. TEMA R-2.31 gives further details.
 Crossflow Tube Layout and Tube Pitch
The fin geometry will have a strong influence on the tube pitch and layout.
Air-cooled heat exchangers
Much greater flexibility is exercised here than in shell and tube exchanger
practice. The minimum pitch is arranged to give a minimum gap > 3mm
between adjacent fin tips. The common TEMA pitch arrangements are used:
Triangular (or staggered): 30 degree layout is common.
Square (in-line): 90 degree possible but seldom used with finned tubes
A common arrangement would be 25.4mm (1 inch) outside diameter tubes
with fins of 57mm (2.25 inch) diameter attached, arranged on a 60mm
(2.375 inch) transverse pitch.
Because the fin pitch is relatively large, pass partitions can usually be
accommodated between standard tube pitches. In some instances, wide
pitching between rows may be required.
Note: For uncommonly large longitudinal pitches, you may have to separately
allow for a reduction in the heat transfer coefficient. Currently this effect is
not allowed for.
 Crossflow Tube Lengths (Maximum)
The most common restriction on the tube length is that imposed by the
maximum available space either in the fabrication shop, in transit or on site.
As far as shop fabrication is concerned, it is probable that the capacity of the
larger works far exceeds anything that the exchanger designer is likely to
require.
If both shop and site have access to deep water then transporting very long
exchangers is no problem. Where delivery must be made by road, the
allowable length will obviously be restricted, probably to around 15 to 20
meters (50 to 65 ft) depending on the country concerned. For any particular
project, the plant operator should advise design engineers of such
restrictions. This information is usually included in the project specification.
While it is relatively easy to get hold of information about maximum shipping
dimensions, it is not always so easy to find out how much space is available
on site. On re-vamp projects or where replacement exchangers are being
fitted, the end user should advise the exchanger designer as to the maximum
plot area available. For new plants the plot plan is hardly ever finalized at the
time exchangers are being thermally designed and the design engineer is
often left to exercise judgment as to the maximum tube length.
Consequently, many engineers tend to use the 'standard' lengths
recommended by TEMA of 2.44, 3.05, 3.66, 4.88 and 6.10 meters (8, 10, 12,
16 and 20 ft). A maximum tube length of six meters is a safe value for
refinery and chemical plant where space is restricted and allowance needs to
be made for withdrawing removable bundles. On gas plants, where very large
single pass exchangers are often used, a much longer maximum length (15
meters or more) is necessary for economic design. On offshore platforms, gas
to gas exchangers are usually installed vertically so that an economic length
can be employed.
 Crossflow Tube Counts
The tube count is the total number of tubes in an exchanger. For this
purpose, a U-tube is counted as two-tubes, so the tube count still gives the
total number of holes in the tubesheet.
Since tubes are laid out in a regular array, calculating the approximate
number of tubes in an exchanger is relatively straightforward.
For the purposes of data consistency in the program you must specify an
exact tube count taking into consideration the type of bundle (e.g. bundle
types 4 and 5 have one less tube in alternate rows.
 Crossflow Extended Surface Types
Extended surface are used on the outside of tubes because tube side heat
transfer coefficients are large (typically in excess of 1000 W/m2 K and can be
higher than 5000 W/m2 K) while the coefficient on the X-side is usually in the
range 10 to 300 W/m2 K. The increase in secondary surface offsets the low
value of the X-side coefficient.
A wide range of extended surfaces is employed and they are manufactured
from many materials. The most common surfaces for air-cooled heat
exchangers consist of smooth aluminum fins helically wound onto low carbon
steel (25.4 mm outside diameter) tubes. The fin height typically ranges from
12 to 24.5 mm, with a mean fin thickness of 0.35 to 1.3 mm and a fin
frequency in the range 160 to 435 fins per meter.
Note that the mean fin thickness for helically wound fins can be calculated
from the stock (or ribbon) thickness by the following equation:

Mean fin thickness, s = D . t

----------
(D + H)

Where, D is the base tube diameter, t is the ribbon thickness and H if the fin
height.
The program can handle a wide range of fin types, e.g. high fins, low fins,
tube-in-plate, studded tubes as well as plain tubes.
 Crossflow Quick Guide to Geometry Selection
The following is a quick guide on how air-cooled exchanger geometry is
selected:

Tube outside diameter - for the process industry 25.4mm (1") tends to be the
most common.
Tube wall thickness - there is no short cut for deciding this. Reference must
be made to a recognized pressure vessel code.
Tube length - for a given surface area the longer the tube length the cheaper
the exchanger, although a long thin exchanger may not be feasible. API 661
requires that an axial flow fan covers at least 40% of the face area of tube
bundle it services. In addition, fewer fans and motors per unit generally leads
to a cheaper design.
Tube layout - A 30-degree layout is often selected as it provides a good
compromise between thermal performance and geometric flexibility.
Tube pitch - This is normally selected to give a minimum fin tip clearance of 3
mm (1/8 inch).
Number of tube passes - is usually one or an even number (not normally
greater than 16). Increasing the number of passes increases the heat transfer
coefficient but care must be taken to ensure that the tube side Rho*V**2 is
not greater than about 10000 kg/m s2.
Nozzles - for tube side nozzles, the maximum Rho*V**2 should not exceed
2230 kg/m s2 for non-corrosive, non-abrasive single phase fluids and 740
kg/m s2 for other fluids.
Fin Diameter - conventional manufacture of tension wound aluminum fins
results in a common maximum of 57 mm (2 1/4 inch) on 25.4 mm (1 inch)
outside diameter tubes. This will be varied to optimize.
Fin Frequency - for cost, heat transfer and pressure drop a common maximum
for commercially manufactured aluminum finned tubes is 433 fins/m (11
fins/inch).
Fin Thickness - thicker fins give higher fin efficiency however the cost of
aluminum dictates a thinner fin, 0.4mm (.016 inch) is a common minimum.
 FiredHeater Headings

Use this sheet to specify information that will appear on the output from the
program.
 FiredHeater Application Options
The Application Options screen contains the following inputs:
Fuel flow fixed/calculated
Draught calculation
Firebox calculation model
Number of process streams
Exclude Firebox from Calculation
Number of convection banks
Flue gas properties
 FiredHeater Streams

The Streams screen contains the following inputs:

Process stream in firebox tubes
Stream name
Total Mass Flow
Inlet Temperature
Outlet Temperature
Inlet Vapor Mass Fraction
Outlet Vapor Mass Fraction
Pressure Drop Calculation Option
Inlet Pressure
Outlet Pressure
Maximum Pressure Loss
Estimated Pressure Loss
Heat Load
Fouling Resistance
 FiredHeater Flue Gas

The Flue Gas screen contains the following inputs:

Total mass flow into convection section
Inlet temperature to convection section
Inlet Pressure to Convection Section
Bridge-wall [firebox exit] temperature
Tube gas-side fouling resistance
Ambient temperature
 FiredHeater Injected Steam

The Injected Steam screen contains the following inputs:

Injected steam mass flow
Steam injection location in firebox
Injected steam pressure
Injected steam temperature
Injected steam vapor fraction

For background information refer to Steam Injection and the Effect of Steam
Injection
 FiredHeater Fuel

The Fuel screen contains the following inputs:

Number of Fuels
Fuel Name
Fuel Type Identifier
Fuel Flowrate
Fuel Inlet Temperature
Atomizing Steam / Fuel Ratio
Atomizing Steam Temperature
 FiredHeater Gaseous Fuel

The Gaseous Fuel screen contains the following inputs:

Fuel Name
Fuel Type Identifier
Mass / Molar Composition
Amount of Component of Gaseous Fuel
Gaseous Fuel
 FiredHeater CHONS Fuel

The CHONS Fuel screen contains the following inputs:

Fuel Name
Fuel Type Identifier
Lower Calorific Value
Fuel Specific Heat
Mass / Atomic Amount
Amount of Elements
 FiredHeater Oxidant

The Oxidant screen contains the following inputs:

Number of Oxidants
Percentage of Excess Air
Percent Oxygen in Flue Gases
Oxidant Name
Relative Mass Flowrate
Oxidant Inlet Temperature
Mass / Molar Composition (of oxidant)
Components of Oxidant
 FiredHeater Layout

The Firebox Layout screen contains the following inputs:

Fired Heater Type
Tube Row Layout
Height
Length
Width
Inner Diameter (cylindrical firebox)
Number of Cells in Multi-cell Firebox
Elevation of Floor of Firebox
Elevation of Top of Firebox
Burner Location
Type of Burner
Number of Burners
Burner Diameter
 FiredHeater Main Tube Rows

The Firebox Main Tube Rows screen contains the following inputs:
Process Stream in Firebox Tubes
Number of Paths in a Firebox Tube Line
Number of Types of Main Tube (Tube Groups)
Orientation of Main Tubes in Firebox
Number of Tube Lines in Multi-cell Firebox
Tube Straight Length
Height of Lowest Tube above Firebox Floor
Tube to Wall Clearance
Tube U-bend Location
Tube Layout Angle
Helical Coil Diameter
Flow Direction in First Tube or Overall
 FiredHeater Roof Tube Rows

The Firebox Roof Tube Rows screen contains the following inputs:
Number of Types of Roof Tube (tube groups)
Roof Tube Orientation
Roof Tube Straight Length
Roof Tube to Roof Clearance
Roof Tube U-bend Location
Roof/Main Tube Flow Sequence
 FiredHeater Tube Groups

The Firebox Tube Groups screen contains the following inputs:

Tube Location (main/roof)
Number of this Size in Series
Tube Material Identifier
Tube Wall Thermal Conductivity
Tube Nominal Bore (inches)
Tube Pipe Schedule
Tube Outside Diameter
Tube Wall Thickness
Tube Spacing
Tube Side Fouling Resistance
Gas Side Fouling Resistance
Number of Paths in a Firebox Tube Line
Total Number of Main Tubes per Firebox
Total Number of Roof Tubes per Firebox
 FiredHeater Gas Offtake

The Firebox Gas Offtake screen contains the following inputs:

Flue Gas offtake Width
Flue Gas offtake Length
Flue Gas Total Exit Area
 FiredHeater Layout

The Convection Banks Layout screen contains the following inputs:

Tube surface enhancement type
Process Stream Number in Bank
Stream inflow from
Stream outflow to
Tube number used in Bank
Number of Rows of Tubes
Number of Tubes in a Row
Tube Orientation in Bank
Flue Gas flow direction
Tube Length
Row Arrangement
Stream overall flow direction
Flow direction in first Tube
Number of parallel Paths/Row
Number of Tubes/Path/Row
Duct Width (transverse to tubes) and Duct other side (parallel to tubes)
Adjoins preceding Bank
 FiredHeater Tubes

The Convection Banks Tubes screen contains the following inputs:

Tube Surface Enhancement Type
Tube Material
Tube Nominal Bore (inches)
Tube Pipe schedule
Tube Outside Diameter
Tube Wall Thickness
Tube Side Fouling Resistance
Gas Side Fouling Resistance
Tube Layout
Tube Pitch
Transverse Pitch
Longitudinal Pitch
 FiredHeater Fins & Studs

The Convection Banks Fins & Studs screen contains the following inputs:
Tube Surface Enhancement Type
Fin Height
Fin Thickness
Fin Frequency
Distance to Plate Fin Inside Edge
Distance to Plate Fin Outside Edge
Stud Height
Stud Thickness
Stud Width
Stud Row Frequency
Number of Studs/Row
Fin or Stud Material
 FiredHeater Stack

The Stack screen contains the following inputs:

Type of Flue/Stack
Stack Diameter at Bottom
Stack Diameter at Top
Height to Bottom of Stack
Height to Top of Stack
Height to Bottom of Transition Region
Height to Top of Transition Region
Height of Damper in Stack
 FiredHeater Ducting

The Ducting screen contains the following inputs:

Diameter of Flue Duct
Width of Flue Duct
Depth of Flue Duct
 FiredHeater Process Streams

The Process Streams screen contains the following inputs:

HTC by HTFS or API Methods
Liquid Phase HTC
Two Phase HTC
Vapor Phase HTC
Liquid Phase HTC multiplier
Two Phase HTC multiplier
Vapor Phase HTC multiplier
 FiredHeater Firebox
The Firebox screen contains the following inputs:
Hottel Bridge-wall Parameter
Bridge-wall (Firebox Exit) Temperature

Heat to Tubes
Tube Gas-side Heat Transfer Coefficient
Tube Wall Thermal Conductivity
Peak Tube Temperature Calculation Method
Longitudinal Heat Flux Variation
Circumferential Heat Flux Variation

Tube Wall Emissivity

Radiation
Firebox Wall Emissivity
Grey Gas Emissivity Model
Amplitude of Grey Gases
Absorption of First Grey Gas
Absorption of Second Grey Gas

Wall Losses
Specify Wall Heat Loss Fraction
Wall Heat Loss Fraction
Firebox Wall Thermal Conductivity
Firebox Wall Thickness
Firebox Inner Wall Heat Transfer Coefficient
Firebox Outer Wall Heat Transfer Coefficient
 FiredHeater Shield Tubes

The Shield Tubes screen contains the following inputs:

Direct Radiation to the Shield Tubes
Radiation Load on Shield Tubes
Radiation Fraction absorbed by First Row
Radiation Fraction absorbed by Second Row
Radiation Fraction absorbed by Third Row
 FiredHeater Flue Gas

The Flue Gas screen contains the following inputs:

Include Radiation from Flue Gas
Gas-side Heat Transfer Coefficient
Tube Wall Thermal Conductivity
Fin or Stud Thermal Conductivity
Heat Loss through Bank Duct Wall
Highfin Heat Transfer Calculation Method
Temperature Drop in Stack
 FiredHeater Air Preheat
The Air Preheat screen contains the following inputs:
Draw-off Fraction (Air-Preheater)
Temperature Drop of Draw-off Gas
Temperature Drop of Remaining Gas
Pressure Change of Drawn-off Gas
Preheater Inlet Air Temperature
Ambient Temperature
Calculate/Set Preheater Flue Gas Temperature Drop
 FiredHeater Firebox Zones

The Firebox Zones screen contains the following inputs:

Number of Gas Zones
Specify Heat Load Fractions in Zones
Flame Length
Fraction along Flame of Heat Release Maximum
Gas or Liquid Fuel
Heat Release Fraction in Zone
 FiredHeater Process Streams

The Process Streams screen contains the following inputs:

Pressure Drop Calculation Option
Pressure Drop Multiplier
Tube-Tube Loss in Firebox (Velocity Heads)
Stream Tube-Tube Loss (Velocity Heads)
Stream Loss after Bank (velocity heads)
 FiredHeater Firebox

The Firebox screen contains the following inputs:

Pressure Change in Inlet Duct to Firebox
Pressure Change across Burner
Pressure Change through Firebox Arch
 FiredHeater Flue Gas

The Flue Gas screen contains the following inputs:

Pressure Loss Coefficient for Damper in Stack
Pressure Change for Extras in Stack
Flue Duct Velocity Head Loss
 FiredHeater Convergence

The Convergence screen contains the following inputs:

Number of Iterations
Relaxation Factor
Convergence Criterion (Temperature)
Convergence Criterion (Pressure)
 FiredHeater Limit Checks

For a number of key parameters relating to the performance of a fired heater,

it is possible for you to specify your own particular limit value, which the
program should check. If you enter such a limit, the program will generate a
warning if this limit is exceeded. Otherwise it will produce a note indicating
that it is not.
This facility can save you the need to find the relevant parameter within the
results and reduce the risk of your missing something that is a potential
problem area. The parameters for which you can request limit checks are:
Peak firebox tube wall temperature
Peak firebox tube heat flux
Maximum firebox process fluid outlet temperature
Maximum tube wall temperature in any convection bank
Maximum gas velocity (mass flux, based on minimum flow area) in any
convection bank
Maximum pressure drop across convection banks (all banks combined)
[Input items 117.1-6 in order above]
 FiredHeater Results Summary

The Results Summary contains the following screens:

Warnings and Messages
Recap of Designs
FiredHeater Summary
 FiredHeater Thermal Hydraulic Summary

The Thermal Hydraulic Summary contains the following screens:

Stream Overview
Bank Performance
Firebox Performance
Flue Gas Overview
Fuel and Oxidant
Solution Overview
 FiredHeater Calculation Details

The Calculation Details output provides tables of results at points with the
firebox and convection banks, rather than just the inlet and outlet values
shown in the Thermal / Hydraulic Summary.
It contains the following screens:
Stream Details
Stream Properties
Zone Details
Draught Details
Flue Gas Properties
 FiredHeater Getting Started Overview
The purpose of this guide is to introduce the basic sequence of entering data
into Aspen FiredHeater. The example that follows uses a Cylindrical Fired
Heater with Vertical Tubes and 2 Convection Banks. The process fluid is
Water.
Help may be obtained at any time by placing the cursor on an item and
pressing F1.
Contents:
Problem Definition
Physical Property Data
Fuel + Oxidant
Heater Geometry - Firebox
Heater Geometry - Convection Banks
Running the Case
Reviewing the Results

Launch the program from either the shortcut or the AspenOne Tool bar.
Select FiredHeater from the New tab and click OK.
Proceed to:
Problem Definition
 FiredHeater Problem Definition
The first item to change is the units, so select from the Program Toolbar the
Units drop-down box and change the units to ‘SI’.

The Application Options screen determines the type of calculation to be

performed and the overall key items such as Number of Process Streams,
Number of Fireboxes. All items can be left as default (Red text) except the
Draught Calculation should be changed to ‘Yes’.
The Heater Diagram tab gives an overview of the Fired Heater configuration.

Within the Process Data section select the Streams tab and enter:
Total Mass Flow = 5.5 kg/s
Inlet Temperature = 10 degC
Outlet Temperature = 400 degC
Inlet Pressure 15 bar
No data is required to be entered into the Flue Gas or Injected Steam tabs.
Proceed to:
Physical Property Data
 FiredHeater Physical Property Data
There is only one process stream to be specified within this heater.
Within the Stream 1 Compositions section select on the Composition tab,
Physical Property Package = ‘B-JAC’. Now click on the ‘Search Databank’
option. This will display a screen where you can search for chemical
components and select as required. For this example enter Water in box 1.
Click on Water within the list in box 2 then click on the Add button. Click OK
and you will be returned to the Composition screen.
Next enter a Composition of 100.

Select within the Stream 1 Properties section the Properties tab. Data such as
pressures and temperatures will have been picked up from previous screens.
Next click on the ‘Get Properties’ button and the property table will be
populated with data across a number of points that will be used when the
calculation is run.
Proceed to:
Fuel + Oxidant
 FiredHeater Fuel + Oxidant
The fuel that will be burnt within the FiredHeater needs to be specified.
Within the Fuel tab, the Fuel Type Identifier lists a number standard fuels -
Select ‘North Sea Gas’ and then enter the following:
Fuel Flowrate = 0.4 kg/s
Fuel Inlet Temperature = 20 degC

The Oxidants screen can be left with the default settings.

Proceed to:
Heater Geometry - Firebox
 FiredHeater Heater Geometry - Firebox
On the Firebox screen the Fired Heater Type can be left as ‘Cylinder’ and the
Tube Row layout as ‘Vertical Tube’.
Enter the following Firebox Dimensions
Height = 12000mm
Inner diameter = 4000mm

Under Burner Details change

Type of Burner = Forced Draught Standard Burner

Next, on the Main Tube Rows screen enter:

Number of Paths in a Firebox Tube Line = 6
Tube Straight Length = 11580mm
There are no Roof Tubes in this heater so select the Tube Groups tab.
Data just for the one tube group needs to be entered:
Number of this size in series = 14
Tube Material Identifier = User Specified
Tube Nominal Bore (inches) = 2.5
The Firebox Diagram illustrates the layout of the tubes in the firebox and the
number of paths specified.
Proceed to:
Heater Geometry - Convection Banks
 FiredHeater Heater Geometry - Convection
Banks
Within the Convection Banks section select the Layout tab where there are 1
tube type to specify.

Bank 1
Number of Rows of Tubes = 2
Number of Tubes in a Row = 12
Tube Length = 4182mm
Number of Parallel Paths/Row = 6

Onto the Tubes tab

The ‘Tube Surface Enhancement Type’ specified on the previous tab is
repeated here for reference.
For Tube 1 enter:
Tube Nominal Bore (inches) = 3
Pipe schedule = 40

The Layout Diagram illustrates the flow path taken within each bank.
Where there is more than one bank, click on each Bank in turn to review the
layout.
The Connections Diagram gives an overview of the Firebox, and order of the
Convection Banks including the flow path of the process stream(s).
Proceed to:
Running the Case
 FiredHeater Running the Case
Now the input is complete the case can be run

Proceed to:
Reviewing the Results
 FiredHeater Reviewing the Results
The Results section becomes available after the run is complete.
The Results Summary includes any calculation messages will be displayed, a
recap of designs and an overall summary of the Fired Heater.
Further details are provided within the Thermal/ Hydraulic Summary and
Calculation Details sections.
The results can be printed out or exported to Excel.
The individual tables in the output screen can be copied to the clipboards and
so pasted in another application. Click the desired table then right-click to
display a menu. Select ‘Copy’ or ‘Copy with description’ then paste into a
suitable application.
 FiredHeater Overview of FiredHeater Models

The following sections give an overview of the types of fired heater which the
program can model.
Overview of the firebox model
Overview of the convection section model
Overview of the flue system model
 FiredHeater Overview of Firebox Model

General
Locating vertical tubes in the firebox
Locating horizontal tubes in the firebox
Firebox zoning (calculation) model
 FiredHeater Overview of Convection Section
Model

The convection section consists of 1 or more tube banks and each bank
comprises a number of rows of identical tubes, with a defined tube pitch and
layout.
The tube banks can have vertical gas flow with horizontal tubes or horizontal
gas flow with either vertical or horizontal tubes. If the convection section
contains only vertical gas flow this is called a Vertical convection section. If it
has only horizontal gas flow it is called a Horizontal convection section. If it
has both vertical and horizontal gas flow it is called a combined convection
section.
The tubes within a bank can be connected in a variety of series and parallel
arrangements, which must be defined in the program input, so that the total
number of parallel paths through which process stream flows can be set
correctly.
Each row of tubes in a tube bank is assumed to be split into a number of
parallel paths, each path containing the same number of tubes. The rows can
be connected in parallel or in series. If the rows are connected in series flow
the process stream flow is split equally between the paths in the inlet row of
tubes and then flows in sequence from the inlet row to the outlet row. If the
rows are connected in parallel flow the process stream is first split equally,
and simultaneously, between all of the tube rows, and then between each
path within the rows.
The basic description of a tube bank thus involves defining;
The number of rows of tubes
The number of parallel paths per row
The number of tubes/row/path
Whether the rows within a group are connected in series or parallel (row
arrangement)
If the rows are connected in series (which is the commonest case), the total
number of parallel paths through the bank is therefore the number of
paths/row.
If the rows are connected in parallel, the total number of parallel paths is the
product of the number of paths/row and the number of rows.
The tube bundle diagrams below are each based on a basic sequence of three
tubes in series, represented by:
Both diagrams show a number of such sequences arranged in four rows, with
a staggered tube layout.

The diagram above shows a tube bank in which the tubes in the rows are
divided into 2 paths with 3 tubes/path/row. The rows are arranged in series
flow and thus the process stream is split equally between a total number of 2
parallel paths. Hence to define this tube bank you would specify;
The number of rows of tubes = 4
The number of parallel paths per row = 2
The number of tubes/path/row = 3
Rows connected in series

The diagram above shows a tube bank with four rows of tubes in which the
tubes in the rows are divided into 3 paths that each contains 3
tubes/path/row. The rows are arranged in parallel flow and the process
stream is split equally between each row and each path in a row and thus is
split equally and simultaneously between a total of 12 paths. Hence to define
this tube bank you would specify;
The number of rows of tubes = 4
The number of parallel paths per row = 3
The number of tubes/path/row = 3
Rows connected in parallel

Note: the program cannot at present deal explicitly with convection banks
where the number of tubes/row/path is different in different rows, or where
the process stream is split simultaneously between a number of tube banks.
Such configurations should be modeled by the nearest permissible
configuration, trying for example to get the same number of total paths in
parallel, and the same total surface area. For example a bank with four rows
of seven tubes, each row having 2 paths but the number of tubes/path/row
being 4,3,4,3 in series for one path, and 3,4,3,4, for the other path could be
modeled as four rows of six tubes, with each path having 3 tubes/path/row
and the tube length set to 7/6 of the actual value.
For a case where a process stream is split simultaneously between different
banks you could create separate FiredHeater cases for each bank and run
each case separately using the appropriate inlet conditions from the other
models until you reach satisfactory convergence. Alternatively you could
defining each split stream as a separate stream, set the inlet conditions for
these streams to estimated values and then run. You could then use the
results from this run to reset the inlet conditions for the streams and run
again. You repeat this procedure until satisfactory convergence is achieved.
 FiredHeater Overview of Flue System Model

If you require a full draught calculation to be carried out on the outlet leg of
your fired heater you may need to specify the heater flue system.
FiredHeater can model either an open flue system in which the flue gases are
exhausted directly to the stack or a complex flue system in which the gases
are passed through ducting prior to entering the stack.
For each of these flue systems you must specify the height and diameter of
the stack and the location of and pressure loss characteristics of the stack
damper. The program will then calculate the flue gas temperature and
pressure change profile in the stack.
In the case of a complex system you must also specify the dimensions of the
ducting and the flue gas temperature and pressure drop that occurs in the
ducting due to the presence of ancillary equipment. For example some ducting
systems contain a heat exchanger for pre-heating the combustion air using
the flue gases as the heat source.
 FiredHeater Heat Flows modeled by Aspen
FiredHeater

When you provide appropriate input information the program can model the
following heat flows:
– Heat input from fuel calorific value
– Air pre-heater duty
– Fuel pre-heater duty
– Sensible heat input from pre-heated air or fuel
– Radiative heat transfer between firebox gases, walls and tubes
– Radiative heat transfer to firebox tubes
– Convective heat transfer to firebox tubes
– Heat loss from firebox walls
– Heat loss in gases leaving the firebox
– Radiative heat load to convection bank shield tubes
– Convective heat transfer to tubes in tube banks
– Heat transfer in fins or studs on convection bank tubes
– Heat transfer to process fluids, single phase or boiling.
– Heat losses to duct walls at and between convection banks
– Extra flue gas heat loss before the flue stack (eg if used for air
pre-heat)
– Heat losses from flue stack walls
– Heat losses up the flue stack
 FiredHeater Fired Process Heaters

Introduction to Fired Heaters

This describes briefly the typical duties for which fired process heaters are
used.
Principal Features
This describes the main parts of a fired heater concerned with burning the
fuel, heat transfer and flue gas disposalMechanical features, such as the
design of the casing, tube supports or refractory linings, are not covered.
Design Considerations
This describes the main points that must be considered in the thermal design
of a fired process heaterThe factors effecting mechanical design are not
discussed.
 FiredHeater Introduction to Fired Heaters

Fired process heaters are used to heat a fluid, flowing inside tubes, by means
of radiative and convection heat transfer from hot combustion gases to the
tubes. They are widely used in the process industries for heating liquids and
gases and for vaporizing duties
They may be gas , oil or dual fired (solid fuels are not used in this type of
heater), and range from small packaged units for supplying hot oil belts to
large and complex units such as Cracking and Steam Reforming Furnaces
Fluid outlet temperatures are generally in the range 500 K (200°C) to 1250 K
(1000°C) and commercial scale units vary in size from around 0.3 MW to 400
MW absorbed duty
The majority are fired continuously for periods of weeks, months or even
years, so considerations of cyclical operation are less important than with
some other types of furnace.

See also:
Typical Duties
Heat Flows modeled by Aspen FiredHeater
Firebox
Fuels
Convection Section
 FiredHeater Principal Features

The principal features of a hypothetical fired process heater, as indicated by a

recirculating fired heater system, comprise the following:
Firebox (sometimes referred to as the Radiant Section), containing:
– Burners
– Radiant Tubes
Convection section containing:
– Shield tube bank
– Extended surface heat recovery tube banks (egwaste heat b oiler,
superheater and/or economizer)
Air Preheater
Induced and Forced Draught Fans
Stack, Dampers, Ducting
Note: Not all heaters will have all these features, the most common
arrangement is a radiant section, convection section and integral stack as
illustrated by an open fired heater system.
 FiredHeater Thermal Design Considerations

Heater Configuration
Efficiency
Exhaust Gas Temperature
Fuels
Burners
Firebox
Radiant Coil
Convection Section
Air Preheaters
Horizontal or Helical Tubes (Design Considerations)
Vertical Tubes (Design Considerations)
Process Fluid Fouling (Design Considerations)
Refractory Backed or Central Tubes (Design Considerations)
 Plate Headings
Use this sheet to specify the following optional information:
Headings - which appear at the top of the Input Summary results, and the
Title Block of the drawings. Headings are 1 to 5 lines of up to 75 characters
per line. Note that only the first 40 characters of each line appear on the
drawings.
Remarks - which appear at the top of the Results – Summary of Input
 Plate: Application Options
The Application Options screen contains the following inputs:
Calculation Mode
Hot Side - Application
Cold Side - Application
 Plate: Calculation Mode
The following Calculation Modes can be selected:
· Design
· Checking
· Simulation
· Design (given plate)
Checking
The program checks whether a heat exchanger of specified geometry will
achieve a specified duty, or specified stream outlet conditions. The result of
this calculation is the ratio of the actual to the required surface area.
Checking or Simulation calculations are performed on a step by step basis
along each pass of the exchanger. 25 calculation steps are used and detailed
allowance can be made for non-linear heat load curves and fluid properties
which vary significantly within the exchanger.
Simulation
You specify the exchanger geometry and the inlet conditions of the hot and
cold streams. The program calculates the stream outlet conditions.
Checking or Simulation calculations are performed on a step by step basis
along each pass of the exchanger. 25 calculation steps are used and detailed
allowance can be made for non-linear heat load curves and fluid properties
which vary significantly within the exchanger.
Design and Design (given plate)
The program provides one or more designs, based on a notional set of plates
held within the program (Design), or on one specified plate (Design (given
plate)).
The program provides one or more designs, based on a notional set of plates
held within the program.
Design and Design (given plate) calculations use a number of simplifications,
such as using average heat transfer coefficients and assuming linear
temperature-enthalpy relations for each stream. For exchangers with only
single phase streams, these assumptions should not lead to significant
inaccuracies, but in other cases, Checking calculations should be performed
once an initial design has been found in Design or Design (given plate) mode.
In Design mode, exchangers are designed by selecting from a notional set of
plates. These have:
· a range of 10 port diameters from 25 mm to 400 mm
· a range of 4 chevron angles 30, 45, 50, 65 (degrees)
· a short, medium and long plate of each type.
The plate geometries from which the program selects are not linked to
products of any particular manufacturer. The corresponding performance data
assumed by the program are also typical values, which do not relate to a
particular manufacturer's products.
Design and Design (given plate) modes (but not Simulation or Checking)
assume that condensing streams are in single pass downflow.
Design (given plate)
The program provides a design (or designs) of an exchanger (or exchangers)
using a plate type which you specify, but adjusting the number of plates and
the pass arrangement to achieve a specified duty.
Design and Design (with given plate) calculations use a number of
simplifications, such as using average heat transfer coefficients and assuming
linear temperature-enthalpy relations for each stream. For exchangers with
only single phase streams, these assumptions should not lead to significant
inaccuracies, but in other cases, Checking calculations should be performed
once an initial design has been found in Design or Design (given plate) mode.
Design and Design (given plate) modes (but not Simulation or Checking)
assume that condensing streams are in single pass downflow.
 Plate: Hot Side - Application
Program
Liquid, no phase change
Gas, no phase change
Phase change

Select the type of process condition existing on the Hot Side.

This determines what input data is required.
 Plate: Cold Side - Application
Program
Liquid, no phase change
Gas, no phase change
Phase change

Select the type of process condition existing on the Cold Side.

This determines what input data is required.
 Plate: Process Data
The Process Data screen contains the following inputs:
Fluid Name
Mass flow rate (total)
Temperature
Vapor mass fraction
Operating pressure (absolute)
Heat exchanged
Adjust if over-specified
Estimated pressure drop
Allowable pressure drop
Fouling resistance
 Plate: Fluid name
Enter a fluid name which will appear on the output.
Each fluid name can be up to 19 characters long and can contain multiple
words.
 Plate: Mass flow rate (total)
Enter the total flow rates for the hot and cold side streams
 Plate: Temperature
Enter the Inlet temperature of the Hot and the Cold sides.
The following Outlet Temperature should be entered:
· For the Hot Side if the application is simple condensation
· For the Cold Side if the application is simple vaporization
For a boiling or condensing stream, you should be careful that the
temperature you supply is consistent with that in the Physical Property input
data, particularly if the boiling or condensing is isothermal.
The outlet temperature is optional for other applications if sufficient data has
been specified to calculate the heat load.
 Plate: Vapor mass fraction
Enter the Vapor mass fraction (mass quality) at inlet for this stream.
All Liquid = 0
All Vapor = 1
This item is normally optional, but input is recommended.
This item must be entered when the stream is isothermal two phase at inlet
(the temperature remains constant with changing enthalpy).
 Plate: Operating pressure (absolute)
You must enter the (absolute) pressure of the stream at the inlet to the heat
exchanger.
This item is needed in all calculation modes.
 Plate: Heat exchanged
Enter a value of the stream heat load. In Simulation mode, this value is
treated as an initial estimate.
This item is may be omitted, if you have supplied data on flowrate and inlet
and outlet temperature, from which it can be calculated, or if you have
supplied a heat load, or data from which it can be calculated, for the other
stream.
 Plate: Adjust if over-specified
Enter a flag to define priorities in determining the stream heat load, in case
the input heat load, and the value calculated from flowrate and inlet and
outlet temperatures are inconsistent.
The flag indicates which parameter for this stream is an approximation, and
should be revised if necessary.
Flowrate
Outlet temperature
Heat load
 Plate: Estimated pressure drop
Enter a value for the Estimated pressure drop permitted for the Hot Side and
the Cold Side
Enter the stream pressure drop. In Design, Design (given plate), or Checking
mode, this value is the required (maximum permitted) pressure drop. This
includes the loss in nozzles, distributors and main fin. There is no default.
For Simulation mode, enter an estimate of the actual pressure drop. The
default is zero.
A number of heat transfer parameters are calculated at the mean stream
pressure, which is assumed to be the inlet pressure less half this pressure
drop.
 Plate: Allowable pressure drop
Enter a value for the maximum pressure drop permitted for the Hot Side and
the Cold Side
In Design, Design (given plate), or Checking mode, this value is the required
(maximum permitted) pressure drop. This includes the loss in nozzles,
distributors and main fin. There is no default.
For Simulation mode, enter an estimate of the actual pressure drop. The
default is zero.
A number of heat transfer parameters are calculated at the mean stream
pressure, which is assumed to be the inlet pressure less half this pressure
drop.
 Plate: Fouling resistance
Enter the fouling resistance (also known as the fouling factor).
Fouling resistances for PHEs are generally low and much less than the TEMA
recommended values for shell and tube exchangers. One fifth or less of the
TEMA value is sometimes suggested.
Fouling in PHEs is often dealt with using an overall fouling margin, rather
than individual fouling resistances for each stream. For Design (or Design
(given plate)) Calculation Modes, you should choose one method or the other,
not both, or fouling will be allowed for twice.
 Plate: Geometry Summary
The Geometry Summary screen contains the following inputs:
Number of exchangers
Double banking option
Number of Passes
Inlet Port Point
Outlet Port Point
Total Number of Channels
Number of Channels in Pass
 Plate: Number of exchangers
The number of exchangers entered is the number of exchangers in parallel
and so the flow rate specified in the Process data is the total flowrate which is
divided equally between the number of exchangers.
 Plate: Double banking option
No
Stream 1
Stream 2

In order to use the double banking option, select which stream is double
banked from the drop down list.
In a normal (i.e. single banked) plate heat exchanger the hot and cold
streams flow in alternate channels ensuring that any two adjacent channels
contain hot and cold streams. In a double banked plate heat exchanger some
of the hot (or cold) channels are adjacent to each other.
The Plate program can handle both fully or partially double banked plate heat
exchangers. While handling a partially double banked exchanger, the Plate
program assumes that the double banking is uniformly distributed within the
exchanger.
Plate can handle double banking for single pass exchangers. Multipass
exchangers are not generally double banked.
 Plate: Number of passes
Enter the number of passes which the Hot Side and Cold Side streams make
through the exchanger.
A pass is a set of parallel flow channels. Most plate exchangers have only one
flow pass, and have all their input and output nozzles on the frame.
Sometimes one or more streams have more than one pass, necessitating
nozzles on the follower. Plate will deal with up to five flow passes and with
the case where the other stream has either a single pass, or the same
number of passes.
 Plate: Inlet port point
Unset
Fixed end: top
Follower: top
Follower: bottom
Fixed end: bottom

Indicate where the stream enters the exchanger.

Looking towards the plate edges, with the fixed end of the frame on the left,
and the follower on the right, the code for the inlet nozzle position is:
1 = Fixed end: top
2 = Follower: top
3 = Follower: bottom
4 = Fixed end: bottom
A single pass stream in upflow would have inlet point at the bottom left, in
downflow the inlet would be top left.
 Plate: Outlet port point
Unset
Fixed end: top
Follower: top
Follower: bottom
Fixed end: bottom

Indicate where the stream leaves the exchanger.

Looking towards the plate edges, with the fixed end of the frame on the left,
and the follower on the right, the code for the outlet nozzle position is:
1 = Fixed end: top
2 = Follower: top
3 = Follower: bottom
4 = Fixed end: bottom
A single pass stream in upflow would have outlet point at the top left, in
downflow the outlet would be bottom left.
 Plate: Total number of channels
Enter the number of channels in which the Hot Side and Cold Side streams
flow - the total over all passes.
The numbers of channels for the two streams should normally either be the
same or differ by one.
 Plate: Number of channels in pass
Enter a number of channels in which this stream flows in each pass, for Hot
Side and Cold Side.
This item can be omitted for single pass streams.
If omitted for multipass streams, the same number of channels in each pass is
assumed.
Pass 1 is on the pass adjacent to the frame (inlet positions 1 and 4 on the
left)
The total number of channels in all passes should add up to the total number
of channels, which can be specified separately.
 Plate: Plate Details
The Plate Details screen contains the following inputs:
Plate data / manufacturer
Plate name
Chevron Angle (to horizontal)
Other Chevron Angle (Mixed Plates)
Horizontal Port Centers Distance
Vertical Port Centers Distance
Plate Thickness
Compressed Plate Pitch
Port Diameter
Plate width
Area of Plate(s)
Number of Plates for Area
User Data

Plate Databank
 Plate: Plate data / manufacturer
This item lets you select options in Plate for setting up plate geometry
information. The options include obtaining data from the plate databank
supplied with Plate.
User Defined
In this case you do not use the plate databank(s), but must directly input the
plate geometry data
Alfa Laval, APV, Tranter.
Select one of these to identify that data from this manufacturer should be
obtained from the new plate databank. A drop down list of plates from this
manufacturer will appear under Plate Name. When you have selected a plate,
the plate geometry information is filled in automatically, and option for
Chevron angle, appropriate to the particular plate, can be selected. Note that
selecting a manufacturer only obtains plate geometry information from that
manufacturer. It does not imply that the calculation methods in the program
are those that the manufacturer would use.
 Plate: Plate name
Depending on the selection in Plate Data / Manufacturer the Plate Name has
three different meanings.
User Defined
No plate name is necessary, but if supplied, Plate will use it as a reference
name.
If you enter a plate name, you do not need to input any more geometry data,
all the necessary data will be obtained from the databank. You may, at your
own risk, input some or all alternative geometry data for a plate. This will be
used instead of what is in the Plate Databank.
Alfa Laval, APV, Tranter
Select the plate name from the drop down menu and then select the Chevron
angle.
Note that when plate databank facility is used, only Plate Geometry data are
obtained from the databank. The correlations used for plate performance are
still the generalized ones normally used in Plate, and not specific ones
provided by the plate manufacturer.
 Plate: Chevron Angle (to horizontal)
Enter the chevron angle. This is defined as the inclination of the corrugation
in the plate to the horizontal.
Low chevron angles give ‘hard’ plates, with relatively high heat transfer and
pressure drop.
High chevron angles give ‘soft’ plates, with relatively low heat transfer and
pressure drop.
If you have selected a Plate Manufacturer and Plate name, this item will
appear as a drop-down, enabling you to select values appropriate to the
particular plate.
If you have selected using the ‘old’ data bank, instead of specifying a
manufacturer, this item should be omitted if a plate name has been specified.

See Also
Other Chevron Angle
Hard Plates and Soft Plates
 Plate: Other Chevron Angle (Mixed Plates)
If your plate exchanger uses mixed (alternating) plates with two different
chevron angles, enter the other chevron angle. When data are obtained from
the Plate databank, this item will appear as a drop-down list.
Note that it is possible to have one chevron angle, but not both, equal to
zero.
With mixed plates, the program calculates an equivalent mean chevron angle.

See Also
Chevron Angle
Hard Pates and Soft Plates
 Plate: Horizontal Port Centers Distance
Enter the horizontal distance between port centers.
If omitted, this item will be estimated using the plate width and port
diameter.
 Plate: Vertical Port Centers Distance
Enter the vertical distance between port centers.
If omitted, this item will be estimated from the plate area and width.
 Plate: Plate Thickness
Enter the thickness of the metal forming the plate.
 Plate: Compressed Plate Pitch
Enter the pitch between plates when compressed in the frame.
For a given exchanger, this may be obtained from by dividing the overall
length of the plate pack (the distance between the two end plates) by the
number of flow channels (or one plus the number of heat transfer plates).

Compressed plate pitch = plate spacing + plate thickness

 Plate: Port Diameter
Enter the internal diameter of the port within the plates.
 Plate: Plate Width
Enter the plate width, i.e. the flow width between gaskets.
If omitted, it will be calculated as the horizontal port centre spacing plus the
port diameter.
 Plate: Area of Plate(s)
Enter the heat transfer surface area either of a single plate, or of a number of
plates (for example a whole exchanger). If you specify the area of multiple
plates, you must also specify the number of plates to which it relates.
Following the usual convention, this is the actual plate area, allowing for
corrugations, not the projected area.
If you omit the area, and have not given a plate name to identify the plate in
the databank, the area will be estimated from the flow width and the vertical
port centers spacing. However, this only gives an approximate value, and is
not recommended.
 Plate: Number of plates for area
Enter the number of heat transfer plates to which the plate area you have
specified relates
Note that exchanger end plates do not count as heat transfer plates.
 Plate: User Data
The plate geometry data can be specified in two ways.
· As Manufacturer Data – In this case the data are obtained from Plate
Data Bank supplied with the Program. These data when populated in various
geometry cells cannot be changed (unless the dropdown list is changed to
User Data).
· As User Data – In this case the user needs to enter the plate geometry
data manually.
 Plate: Plate databank
The Plate Geometry databank provided with Plate contains information on
plate geometries supplied to Aspen EDR by leading manufacturers of plate
heat exchangers. When you use the databank, you can interactively select
the plate manufacturer, the manufacturer’s plate code, and the plate chevron
angle. The remainder of the plate geometry information is picked up from the
plate databank.
Note that when you select manufacturer’s data in this way, it is only the plate
geometry information that is used by Plate. The performance data for heat
transfer and pressure drop used are those of EDR, not the plate
manufacturer. At the request of one manufacturer, Plate contains a disclaimer
to emphasize this point.
The Plate Geometry information is held in an Access database. The database
file is called PlateDB.mdb and is stored in the program directory. The plate
data bank can be extended by either editing the Access database file directly
or using the Plate+DB.exe utility.
Use of the databank is optional. Select User Defined in Plate Data /
Manufacturer dropdown menu so that you can enter the plate geometry
information manually.
See Also
Plate Name
 Plate: Asymmetric Plates
The Asymmetric Plates screen contains the following inputs:
Plate Pitch Option
Hot Stream is on Side One
Compressed Plate Pitch on Side One
Compressed Plate Pitch on Side Two
 Plate: Plate Pitch Option
Symmetric
Asymmetric

Normally, PHEs are configured to have the same plate gap for hot and cold
streams. This is referred to as Symmetric Plate Pitch Option.
In order to handle viscous fluids or suspensions, a plate configuration that will
provide a wider plate gap for one of the streams is used. This is referred to
Asymmetric Plate Pitch Option.
 Plate: Hot Stream is on Side One
When Plate Pitch Option is set to Asymmetric, you can set the location of the
Hot Stream.
 Plate: Compressed Plate Pitch on Side One
Enter the pitch between plates when compressed in the frame.
For a given exchanger, this may be obtained from by dividing the overall
length of the plate pack (the distance between the two end plates) by the
number of flow channels (or one plus the number of heat transfer plates).

Compressed plate pitch = plate spacing + plate thickness

 Plate: Compressed Plate Pitch on Side Two
Enter the pitch between plates when compressed in the frame.
For a given exchanger, this may be obtained from by dividing the overall
length of the plate pack (the distance between the two end plates) by the
number of flow channels (or one plus the number of heat transfer plates).

Compressed plate pitch = plate spacing + plate thickness

 Plate: Exchanger Diagram
An Exchanger Diagram can be generated in two ways.
For a Checking or Simulation case the diagram provides a representation of
the data you have input, and thus provides a useful visual check that you are
correctly representing the exchanger you wish to model. It also includes
information (input or assumed) on stream inlet and outlet locations, and inlet
and outlet temperatures.
An equivalent diagram is available after Plate has been run, but giving you
either the geometry assumed in the calculation (which may include defaults)
or the geometry resulting from the calculation, as when a Design case has
been run.
The input exchanger diagram is not available at input if you use the facility to
specify plates in the plate databank supplied with Plate, but you can view the
diagram under the Output menu, after running the program.
When the diagram window is open, the diagram menu is available.
 Plate: Materials of construction
The Exchanger Configuration Details screen contains the following inputs:
Plate material
User input thermal conductivity
 Plate: Plate material
Stainless
Titanium
User Specified

Plate permits the exchanger metal to be defined as being stainless steel (the
default), titanium or user specified. This value affects the thermal
conductivity of the plates used in the heat transfer calculations.
 Plate: User input thermal conductivity
Enter the thermal conductivity of the tube material, only if you wish to
override the value determined for the specified plate material.
If you have specified the plate material as "user specified", the default value
of 10 W/mK is displayed which can then be changed to an appropriate value.
 Plate: Process Limits
The Process Limits screen contains the following inputs:
Maximum % pressure drop in ports
Percent fouling margin
 Plate: Maximum % pressure drop in ports
The following two considerations give the maximum allowable % pressure
drop in ports
For U configuration the ratio of port pressure drop to total pressure drop (port
+ plate) should be less than 45%.
For Z configuration the ratio of port pressure drop to total pressure drop (port
+ plate) should be less than 30%.
 Plate: Percent fouling margin
For plate heat exchangers allowance is often made for uncertainties in the
exchanger performance by using a Design Margin, which is often referred to
as a Fouling Margin. In Plate it is expressed as a percentage, and appears on
the Options/Calculation Options input screen.
This margin is used directly in Design and Design (given plate) Calculations,
in that designs are only accepted if they have an area ratio greater than the
specified margin.
In Checking and Simulation calculations, the Design Margin is not explicitly
allowed for, although in the results from a Checking Calculation, the
calculated area ratio is compared with the specified margin.
Care should be taken if a Design (fouling) Margin is specified as well as
Fouling Resistances.
Fouling Resistances in Plate Heat exchangers are often not known explicitly.
They are almost certainly less, by a factor of 5 or more, than the fouling
resistances often used for shell and tube exchangers This arises because the
flow uniformity is better, and the local shear rate higher, in a Plate exchanger
than in a shell and tube exchanger
Plate permits both an overall fouling margin and fouling resistances for
individual streams to be input, and applies them cumulatively. For this
reason, in Design or Design (given plate) Calculation Modes you should input
either resistances, or a margin, but not both. If you do not have information
on individual stream fouling resistances available, then leave them unset (or
set to zero) and specify a fouling margin.
Fouling margins are typically set to ten percent for clean fluids, or 20 percent
for dirty fluids. In exceptional circumstances, higher values may be used.
 Plate: Heat Transfer/Hydraulics
The Heat Transfer/Hydraulics screen contains the following inputs:
Liquid heat transfer coefficient
Two phase heat transfer coefficient
Vapor heat transfer coefficient
Liquid heat transfer coefficient multiplier
Two phase heat transfer coefficient multiplier
Vapor heat transfer coefficient multiplier
Pressure drop multiplier
 Plate: Liquid heat transfer coefficient
If you wish, you may enter a value for the liquid heat transfer coefficient here
to override the calculated value.
Program calculated values should normally be used, unless you have a very
good reason for overriding them.
 Plate: Two phase heat transfer coefficient
If you wish, you may enter a value for the two phase (boiling or condensing)
heat transfer coefficient here to override the calculated value.
Program calculated values should normally be used, unless you have a very
good reason for overriding them.
 Plate: Vapor heat transfer coefficient
If you wish, you may enter a value for the vapor heat transfer coefficient here
to override the calculated value.
Program calculated values should normally be used, unless you have a very
good reason for overriding them.
 Plate: Liquid heat transfer coefficient multiplier
A value entered here can be used to increase or decrease the calculated liquid
heat transfer coefficient.
Program calculated values should normally be used unchanged, unless you
have a very good reason for scaling them.
 Plate: Two phase heat transfer coefficient
multiplier
A value entered here can be used to increase or decrease the calculated
boiling or condensing heat transfer coefficient.
Program calculated values should normally be used unchanged, unless you
have a very good reason for scaling them.
 Plate: Vapor heat transfer coefficient multiplier
A value entered here can be used to increase or decrease the calculated vapor
or gas heat transfer coefficient.
Program calculated values should normally be used unchanged, unless you
have a very good reason for scaling them
 Plate: Pressure drop multiplier
Enter the number by which the calculated frictional pressure gradient (liquid,
two phase or vapor) should be multiplied. It is not possible to scale the
pressure drops of each phase separately.
Program calculated values should normally be used unchanged, unless you
have a very good reason for scaling them
 Plate: General
The General screen contains the following inputs:
Correlations to be used
Flow Maldistribution Calculation
 Plate: Correlations to be used
Latest HTFS methods
Pre-2006.5 methods

The program contains generic plate performance data for plates which form
cross-corrugated flow channels. The Pre-2006.5 methods are described in
Design Report DR36 and Latest HTFS methods are described in Research
Report RS 1189 (2006).
These documents are accessible to customers licensing the Aspen HTFS
Research Network.
See also:
Plate performance analysis method
 Plate: Flow maldistribution calculation
Yes if needed
Yes
No

Flow maldistribution may occur when there are a large number of plates, and
the flow of a single pass stream has to be distributed among a large number
of channels in parallel. The flow resistance in the ports associated with
channels distant from inlet and outlet can be significantly more than in
channels nearer to the inlet and outlet, with the result that the distant
channels receive a lower than average flow and the near channels a higher
flow.
Plate initially assumes that there is uniform distribution of the flow of each
stream among the various flow channels between plates. Plate can both
perform an assessment of whether flow maldistribution effects may be
significant, and then evaluate the effect of such maldistribution on thermal
performance.
 Plate: Performance Data
The Performance Data screen contains the following inputs:
Plate Pitch Option
Hot Stream is on Side One
Performance Analysis Method
Reynolds Number
Colburn j Factor
Friction Factor

The program contains generic plate performance data for plates which form
cross-corrugated flow channels. Therefore you will not normally need this
facility to input plate performance data. However, it may be useful in the
following situations.
· You have more accurate performance data for a specific plate
· You want to use the program for handling plate geometries other than
cross-corrugated, e.g. dimpled plate
These Performance Analysis Methods are available in all the calculation modes
except Design mode.
 Plate: Performance Analysis Method
Plate method
Specify Colburn j & Friction Factors
Specify Friction Factors only
Specify Colburn j factors only

The program contains generic plate performance data for plates which form
cross-corrugated flow channels. These performance data are based on HTFS
proprietary methods. Therefore, you will not normally need this facility to
input plate performance data. However it may be useful in the following
situations:
· You have more accurate performance data for a specific plate
· You want to use the program for handling plate geometries other than
cross-corrugated, e.g. dimpled plate
This feature exists in all the calculation modes except Design mode.
 Plate: Reynolds Number
Reynolds numbers can be any order, but no two should be the same. Regions
of laminar, transition and turbulent flow can be covered in the table. The
program will interpolate the data on a log-log basis and if required, the data
will be extrapolated on a log-log basis, but a warning message will be issued
to indicate that the data have been extrapolated.
The definition of Reynolds number used by the program for Newtonian fluid:

Reynolds number for Non-Newtonian fluids:

The mass flux in both equations is based on the flow area between the plates
and the equivalent diameter:

If the plate development ratio is not known, a value of 1.17 should be used. b
is the Compressed plate pitch
Range of Data
0.1 to 10,000 (Expected)
0.01 to 100,000 (Permitted)
Notation
Equivalent
m
diameter

Consistency coefficient

Mass flux kg/m²s

Non-Newtonian power index

Plate development ratio

Density kg/m³

See also:
Performance Data
Colburn j Factor
 Plate: Colburn j Factor
For each Reynolds Number in the Performance Data table, enter an associated
heat transfer factor (the Colburn j factor). The program uses the supplied
data to calculate the local heat transfer coefficient in the form of:

The mass flux is based on the flow area between the plates. The Colburn j
factor that is used in the performance data is assumed to be dependent only
on Reynolds Number and not on Prandtl number. If user supplied Colburn j-
factor data includes a dependence on Prandtl Number, then you could use an
average value of Prandtl number, since there is no correction of the Colburn
j-factor due to the Prandtl number effect in the program.
Range of Data
1e-10 to 500 (Expected & permitted)
Notation
Colburn j factor

Specific heat capacity J/kg K

Mass flux kg/m²s

Prandtl number

Heat transfer
W/m²K
coefficient

See also:
Performance Data
Reynolds Number
 Plate: Friction Factor
For each Reynolds Number in the Plate Performance data table, enter an
associated friction factor. The defining equation for the friction factor is:

The mass flux is based on the flow area between the plates and the
equivalent diameter is defined as thus.

If the plate development ratio is not known a value of 1.17 should be used. b
is the Compressed plate pitch.
Range of data
1e-10 to 500 (Expected & permitted)
Notation
Compressed plate
m
pitch

Equivalent diameter m

Friction factor

Mass flux kg/m²s

Pressure Pa

Distance m

Plate development ratio

Density kg/m³

See also:
Performance Data
Reynolds Number
Colburn j Factor
 Plate: Results
The results are divided into the following sections:

Input Summary

Results Summary
Warnings & Messages
Optimization Path
Recap of Designs

Thermal / Hydraulic Summary – Performance

Overall Performance
Resistance Distribution

Thermal / Hydraulic Summary – Heat Transfer

Heat Transfer Coefficients
Duty Distribution

Thermal / Hydraulic Summary – Pressure Drop

Pressure Drop

Thermal / Hydraulic Summary – Methods

Methods Summary

Mechanical Summary
Exchanger Geometry
Exchanger Diagram

Calculation Details
Hot Side Calculation Details
Cold Side Calculation Details
 Plate: Input Summary
This section provides you with a summary of the information specified in the
input file.
It is recommended that you request the input data as part of your printed
output so that it is easy to reconstruct the input, which led to the design.
 Plate: Warnings & Messages
Plate provides an extensive system of errors, warnings and other messages to
help you use the program. They are for the most part self explanatory, and
contain information on the values of parameters which have led to the
reported condition. There are several hundred messages built into the
program, and these can be divided into number of types
Range Checking Warning.
These relate to input values which are outside the range of what is normally
expected. You should check that the input value referred to is correct. If so
the message can usually be ignored, although for unusual exchanger
geometries, or unusual fluid properties, it is likely that the uncertainty in the
results is exacerbated.
Input Omission Error
These identify input parameters which are necessary for the program to run.
Whether a particular parameter is necessary can depend on the values of
other parameters. Required input is normally identified in the User interface,
although there are occasionally instances where a required item is not
highlighted in the Interface, or where an item is shown as required by the
interface, does not lead to an error when the program is run.
Range Checking Error
These identify input values which are beyond the range of what is permitted.
They cause program execution to cease.
Results Warning
The run has completed, but problems have been identified with some part of
the calculation, which indicate that some aspect of the results may be subject
to more uncertainty than normal.
Results Error
The run has either failed to generate a significant part of the results, or failed
to complete in some way that many of the results given should not be relied
on..
Operation Warning
The run has completed, but is predicting operation which does not meet
normal practice, or is in some other way inadvisable, or in extreme cases
impracticable.
Advisory
There is some feature of the exchanger, or its operation which is unusual, and
for which better alternatives may exist
Notes
Any other information which may be useful
 Plate: Optimization Path
This part of the output is the window into the logic of the program. It shows
some of the heat exchangers the program has evaluated in trying to find one,
which satisfies your design conditions. These intermediate designs can also
point out the constraints that are controlling the design and point out what
parameters you could change to further optimize the design.
To help you see which constraints are controlling the design, the conditions
that do not satisfy your specifications are noted with an asterisk (*) next to
the value. The asterisk will appear next to the required tube length if the
exchanger is undersurfaced, or next to a pressure drop if it exceeds the
maximum allowable.
In design mode, Plate will search for a heat exchanger configuration that will
satisfy the desired process conditions. It will automatically change a number
of the geometric parameters as it searches. However Plate will not
automatically evaluate all possible configurations, and therefore it may not
necessarily find the true optimum by itself. It is up to the user to determine
what possible changes to the construction could lead to a better design and
then present these changes to the program.
Plate searches to find a design that satisfies the following:
(1) enough surface area to do the desired heat transfer
(2) pressure drops within the allowable
(3) physical size within acceptable limits
(4) velocities within an acceptable range
(5) mechanically sound and practical to construct

There are over thirty mechanical parameters which directly or indirectly affect
the thermal performance of a shell and tube heat exchanger. It is not
practical for the program to evaluate all combinations of these parameters. In
addition, the acceptable variations are often dependent upon process and cost
considerations which are beyond the scope of the program (for example the
cost and importance of cleaning). Therefore the program automatically varies
only a number of parameters which are reasonably independent of other
process, operating, maintenance, or fabrication considerations.
 Plate: Recap of Designs
The recap of design cases summarizes the basic geometry and performance of
all designs reviewed up to that point. The side by side comparison allows you
to determine the effects of various design changes and to select the best
exchanger for the application. As a default, the recap provides you with the
same summary information that is shown in the Optimization Path. You can
customize what information is shown in the Recap by selecting the Customize
button. You can recall an earlier design case by selecting the design case you
want from the Recap list and then select the Select Case button. The program
will then regenerate the design results for the selected case.
 Plate: Overall Performance
In the general performance section, flow rates, gases (in/out) and liquids
(in/out), for the hot side and the cold side are shown to summarize any phase
change that occurred in the exchanger.
The Temperatures (in/out) for both sides of the exchanger are given along
with dew point and bubble point temperatures for phase change applications.
Film coefficients for the shell and tube sides are the weighted coefficients for
any gas cooling/heating and phase change that occurred in the heat
exchanger.
Velocities for single phase applications are based on an average density. For
condensers, the velocity is based on the inlet conditions. For vaporizers, it is
based on the outlet conditions. Outside velocities are the crossflow velocity
through the cross-section.
Overall performance parameters are given, such as Heat exchanged, MTD
with any applied correction factor and the effective total surface area. For
single phase applications on both sides of the shell, a MTD correction factor
will be applied in accordance with TEMA standards. For multi-component
phase change applications, the MTD is weighted based upon a heat release
curve.
The Heat Transfer Resistances are graphically displayed on the Heat Transfer
Resistance Diagram at the bottom of the screen.
 Plate: Resistance Distribution
This screen gives information to help you evaluate the surface area
requirements in the clean, specified fouled/dirty (as given in the input), and
the maximum fouled/dirty conditions.
The clean condition assumes that there is no fouling in the exchanger, in the
new condition. The overall coefficient shown for this case has no fouling
resistance included. Using this clean overall coefficient, the excess surface
area is then calculated.
The specified foul condition summarizes the performance of the exchanger
with the overall coefficient based upon the specified fouling.
The maximum fouled condition is derived by taking the specified fouling
factors and increasing them (if the exchanger is oversurfaced) or decreasing
them (if undersurfaced), proportionately to each other, until there is no over
or under surface.
The distribution of overall resistance allows you to quickly evaluate the
controlling resistance(s). You should look in the "Clean" column to determine
which film coefficient is controlling, then look in the "Spec. Foul" column to
see the effect of the fouling resistances. The difference between the excess
surface in the clean condition and the specified fouled condition is the amount
of surface added for fouling.
You should evaluate the applicability of the specified fouling resistances when
they dictate a large part of the area, say more than 50%. Such fouling
resistances often increase the diameter of the heat exchanger and decrease
the velocities to the point where the level of fouling is self-fulfilling.
The Heat Transfer Resistances are graphically displayed on the Heat Transfer
Resistance Diagram at the bottom of the screen.
 Plate: Heat Transfer Coefficients
This output section shows the various components of each film coefficient
Depending on the application, one or more of the following coefficients are
shown:
desuperheating
condensing
vapor sensible
liquid sensible
boiling
liquid cooling
The Reynolds number is included so that you can readily evaluate if the flow
is laminar (under 2000), transition (2000-10000), or turbulent (over 10000).
The fin efficiency factor is used in correcting the tube side film thermal
resistance and the tube side fouling factor resistance.
Plate: Duty Distribution
 Plate: Pressure Drop
The pressure drop distribution is one of the most important parts of the
output for analysis. You should observe if significant portions or the pressure
drop are expended where there is little or no heat transfer (inlet port, outlet
port).
If too much pressure drop occurs in an inlet/outlet port, consider increasing
the port size.
The program determines the dirty pressure drop by estimating a thickness for
the fouling, based on the specified tube side fouling resistance, which
decreases the cross-sectional area for flow.
The velocity distribution, between the inlet and outlet nozzle, is shown for
reference. In other parts of the output, the velocity, which is shown for the
shell side, is the diametric cross flow velocity. For the tube side it is the
velocity through the tubes. For two phase applications, the velocities for cross
flow, through baffle windows, and through tubes are the highest velocities
based on the maximum vapor flow.
 Plate: Methods Summary
This screen lists all the models and methods that have been used by the
program as part of the calculations.
 Plate: Exchanger Geometry
The geometry used in the calculations is summarized in a series of sections:
Exchanger Details
Exchanger Configuration
Channels in each Pass
Plate Details
 Plate: Hot Side Calculation Details
The Hot Side Calculation Details section includes the following screens:
Interval Analysis
Plots
 Plate: Interval Analysis
The Interval analysis section provides you with a table of values for liquid
properties, vapor properties, performance, heat transfer coefficients and heat
load over the hot side and cold side temperature ranges.
 Plate: Plots
This tab allows you to create plots from the data displayed in the interval
analysis tables.
Select an X variable and a Y variable to create the required plot.
Various controls are available for zoom-in/out, printing, copying, or saving
the plots.
 Plate: Cold Side Calculation Details
The Cold Side Calculation Details section includes the following screens:
Interval Analysis
Plots
 Plate: Getting Started Overview
The purpose of this exercise is to design a simple single-phase heat exchanger
using Aspen Plate. The Design calculation will determine the size of the
exchanger.
Help may be obtained at any time by placing the cursor on an item and
pressing F1.

Contents:
Problem Definition
Physical Property Data
Running the Case - Design mode
Reviewing the Results
Creating a Checking Case
Running the Case - Checking mode
Reviewing the Results

Launch the program from either the shortcut or the AspenOne Tool bar.
Select Plate from the New tab and click OK.
Proceed to:
Problem Definition
 Plate: Problem Definition
The first item to change is the units, so select from the Program Toolbar the
Units drop-down box and change the units to SI.

The Application Options screen determines the type of calculation to be

performed and the Hot Side and Cold Side applications. These can all be left
at their default values.
The Process Data for this example is listed in the following table:
Hot Side Cold Side
Fluid Units
Fuel Oil Boiler Feedwater

Total Flowrate kg/h 340 230

Temperature (In/ Out) °C 113 / 100 80 / 90

Operating Pressure
bar (abs) 8 13
(absolute)

Fouling Resistance (min) m2 °K/W 0.00002 0.00002

Proceed to:
Physical Property Data
 Plate: Physical Property Data
On the Hot Side Composition screen select for Physical Property Package =
‘User Specified Properties’.
Next select the Hot Stream Properties section and the Properties tab.
Into the table enter:
Temperature C 213 168

Liquid density kg/m3 879.4 909.8

Liquid specific heat kJ/(kg*K) 2.34 2.18

Liquid viscosity mPa*s 1.94 3.37

Liquid thermal cond. W/(m*K) 0.1 0.107

By default, two pressure levels are available, where in this example data at
only one pressure level is to be entered. To delete the second pressure level
you have two options:
Highlight the second pressure level in the Pressures column then click on the
Delete Set button.
Note: The Overwrite properties box is checked for direct input of properties.
Now select the Compositions tab within the Cold Stream Compositions section.
For the Physical Property Package select ‘B-JAC’
Now click on the ‘Search Databank’ option. This will display a screen where
you can search for chemical components and select as required. For this
example enter Water in box 1. Click on Water within the list in box 2 then
click on the Add button. Click OK and you will be returned to the Composition
screen.
Next enter a Composition of 100.
Select within the Cold Stream Properties section the Properties tab. Data such
as pressures and temperatures will have been picked up from previous
screens.
Next click on the ‘Get Properties’ button and the property table will be
populated with data across a number of points that will be used when the
calculation is run.
Proceed to
Running the Case - Design mode
 Plate: Running the Case - Design mode
As this is a design case not geometry needs to be entered.
Click Run.

Proceed to
Reviewing the Results
 Plate: Reviewing the Results
The Results section becomes available after the run is complete.
The Results Summary includes any calculation messages will be displayed, a
recap of designs and an overall summary of the Plate Exchanger.
Further details are provided within the Thermal/ Hydraulic Summary and
Calculation Details sections.
Proceed to
Creating a Checking Case
 Plate: Creating a Checking Case
The exchanger design can now be converted into a checking case.
From the ‘Run’ drop-down menu select ‘Update file with geometry – Plate’
On the Applications Option screen, the Calculation mode will now be set to
Rating / Checking.
Proceed to
Running the Case - Checking mode
 Plate: Running the Case - Checking mode
Click Run.
Proceed to
Reviewing the Results
 Plate: Reviewing the Results
The results can be printed out or exported to Excel.
The individual tables in the output screen can be copied to the clipboards and
so pasted in another application. Left mouse-click on the desired table then
right-mouse click to display a menu. Select ‘Copy’ or ‘Copy with description’
then paste into a suitable application.
 Plate: Plate Heat Exchanger Overview
Plate can model Plate Heat Exchangers (PHE) with a cross-corrugated flow
pattern.
e.g. Plate and Frame exchangers, Brazed Plate and Welded Plate

See also:
Flow Passage Structure in Plate Heat Exchangers
Operating Temperatures and Pressures
Modeling and Design of PHE's
 Plate: Plate and Frame Heat Exchangers
The plate and frame exchanger, also referred to as the plate heat exchanger,
consists of a pack of plates held together in a frame. Plates can be from 0.2m
to over 3m long, while their width is typically 20 to 40 percent of their length.
The two streams flow in alternate channels between plates, entering and
leaving via ports in the corner of the plates. On each plate, there is usually a
gasket round the edge, and around the ports. The exchanger can be
completely dismantled for cleaning, which makes it very suitable for the food
industry and other hygienic applications.
The typical chevron pattern on plates gives cross corrugated passages in the
plate heat exchanger. Plates are made from materials which can be pressed,
stainless steel being the most common material of construction. The plate
thickness is normally in the range of 0.4 to 0.9 mm, while the plate spacing
lies between 2.5 and 5 mm, except for special wide-gap plates sometimes
used for viscous or fibrous materials. The hydraulic diameter for flow between
plates approximates to twice the plate spacing.
Plate: Plate and Frame Heat Exchanger
 Plate: Brazed Plate Heat Exchangers
This has a similar basic plate structure to a conventional plate heat
exchanger, but the pack of plates is brazed together using copper as a brazing
material. Brazing eliminates the need for either a frame or gaskets, and gives
a very inexpensive exchanger. Instead of copper, nickel is used for brazing
when copper presents a compatibility problem with a process stream such as
ammonia. Exchanger lengths are usually one meter or less, although larger
units are being continuously introduced in the market.
 Plate: Flow Passage Structure in Plate Heat
Exchangers
The common feature of all plate heat exchangers is the use of corrugations in
the plates, giving both support against internal pressures and heat transfer
enhancement. The most common type of plate uses cross corrugations, which
provide a lattice of support points where they touch, and form a complex flow
channel shape between the plates. The corrugations are usually formed as
chevrons. There may be a single chevron pattern or multiple chevrons across
the plate width. Other variants have the chevron pattern running along the
length of the plate. In all cases, however, the local flow geometry has the
same cross corrugated structure.
For the cross corrugated plates formed from a chevron pattern, chevron angle
is an important variable. The chevron angle is referred to here as the angle of
the corrugations with respect to a horizontal line. A low chevron angle plate
gives high heat transfer and high pressure drop whereas a high chevron angle
plate gives lower heat transfer as well as lower pressure drop. The low and
high chevron angle plates are also referred to as hard plates and soft plates
respectively, reflecting the resistance that they present to a flowing fluid. The
chevron angle is a key design parameter.
In addition to the main chevron pattern, the pattern on the distribution
regions of the plates is also important. It can play a significant role in uniform
distribution of a stream in a given plate channel.
 Plate: Operating Temperatures and Pressures
For plate heat exchangers, operating pressures up to 25 bar are standard,
while somewhat higher pressures can be achieved using heavy duty frames.
Temperatures are usually limited by the gasket. Upper limits of 160º to
180ºC apply to most gasket materials. Gasket quality can also affect the
operating pressure and temperature. The APV company introduced a graphite
based gasket, claimed to operate up to temperatures of 400ºC. For duties
where a suitable gasket material is not available, plate pairs are welded round
the edge. Gaskets are then used between the welded pairs for the less
aggressive fluid. Alfa-Laval has produced a gasket free version where a
completely welded plate pack is held in a conventional manner within a
frame. This exchanger can be operated up to 350ºC temperature and 40 bar
pressure. However, as a result of welding it can not be opened for cleaning or
any other purpose.
 Plate: Modeling and Design of PHE's
Design involves determining an exchanger geometry. The involves selecting a
plate, and then determining an overall exchanger geometry
There are six key parameters which define the basic geometry of a plate
Port diameter
Port spacings, horizontal and vertical (or plate length and width)
Heat transfer area (closely related to port spacing parameters)
Plate thickness
Chevron angle
In order to define the overall exchanger geometry, the following parameters
are necessary.
Number of hot stream passes
Number of cold stream passes
Number of channels (or plates) in each pass
Number of exchangers in parallel
Whether each stream is (initially) in upflow or downflow
If an existing design is to be modeled, the above items need to be provided as
geometry input.
The simplest design of plate heat exchanger uses a preselected plate. This
would be done when an existing exchanger needs to have plates added to
meet a new larger duty. Only the second set of parameters listed above need
then be determined. Since most plate exchangers have a single pass for each
fluid, and hot and cold channels must alternate, the design process simplifies
to finding the smallest number of plates which will meet heat transfer and
pressure loss requirements.
More generally a plate exchanger design program must also select the plate
type. The initial selection of plate type is normally based on a recommended
maximum port velocity at inlet. The smallest port size that meets this
constraint for both streams is chosen. The port size effectively determines the
plate width. There are then two more key parameters for each plate, the
length and the chevron angle. Plate area can be estimated from the length
and width. The thickness depends on design pressure. For a particular plate
width, there could in principle be a range of plate lengths. Since each plate
geometry involves its own mould for pressing, manufacturers produce only a
limited number of lengths for a given port size / plate width; often there is
only one length. A design program can allow for a short, medium and long
version of each plate.
The chevron angle of plate corrugations determines how 'hard' or 'soft' it is.
Hard plates offer high heat transfer at the expense of high pressure drop, and
have relatively low chevron angles, such as 300 to the horizontal. Soft plates
have reduced heat transfer and pressure drop, and chevrons at an angle such
as 600 with the horizontal. Although there are various guidelines available to
suggest when hard, soft or medium plates should be used, there is little point
in attempting to reproduce them in a computer code. It is simpler to scan
through a range of possible chevron angles, and produce a design (or designs)
using each. It is then clearly apparent which chevron angle produces the best
design for a particular case.
Design software for plate heat exchangers thus needs to follow a relatively
simple set of procedures, and need define only about ten parameters. The
complications arise when dealing with difficult cases, such as when port
pressure losses consume all the available pressure drop, or plate packs that
become so long that there is a risk of maldistribution among the channels. A
range of plates with different port sizes must then be tried. If in spite of all
these trials the risk of flow maldistribution can not be avoided, the program
should highlight the risk in such designs. The actual effect of flow
maldistribution on the exchanger performance can then be investigated in the
program’s performance mode of calculation.
 PlateFin: Thermal Design of Plate-fin Heat
Exchangers
PlateFin Input
PlateFin Results
PlateFin Getting Started Guide
Plate-fin Exchangers
PlateFin How to Use the Program
PlateFin MUSE and PlateFin
 PlateFin: Input
Problem Definition
Headings/Remarks
Application Options
Process Data

Physical Property Data

Stream Composition
Stream Properties

Exchanger Geometry
General
Layer Types
Distributors
Exchanger Diagram
Fins
Fin Performance
Thermosiphons
Pipework

Program Options
Design Options
Thermal Analysis
Calculation Options
 PlateFin: Problem Definition

The Problem Definition section includes the following sections:

Headings/Remarks
Application Options
Process Data
 PlateFin: Headings/Remarks
The Headings/Remarks section includes the following screens:
Headings
 PlateFin: Headings
The Headings appear at the top of the results sheets.
Headings are 1 to 5 lines of up to 75 characters per line. Note that only the
first 40 characters of each line appear on the drawings.
Remarks appear at the bottom of the results specification sheet.
 PlateFin: Application Options
The Application Options screen includes the following inputs:
Calculation Mode
Exchanger Type
Number of Streams
Number of Fins
Number of Layer Types
Number of Thermosiphon Streams
Number of Distributor Types
 PlateFin: Calculation Mode
There are two Simulation options and one Design option. Both Simulations
use specified inlet conditions of each stream, and predict the outlet
conditions. The exchanger geometry must be specified. For Design, the
required inlet and outlet conditions must both be specified. No geometry data
are needed.
Stream by stream simulation: In calculating stream outlet conditions for each
stream, the program uses an overall metal temperature profile along the
length of the exchanger. This is the common wall temperature assumption.
Specification of the layer pattern is optional; the program just needs to know
the number of layers of each type. It effectively assumes that the layer
pattern is good.
Layer by layer simulation: In calculating stream outlet conditions for each
stream, the program does separate calculations for every layer in the
exchanger and derives the metal temperature profile along every parting
sheet between layers. The layer pattern (stacking pattern) must be specified.
The calculation effectively evaluates how good the layer pattern is. The
detailed metal temperatures it produces can be used to assess thermal
stresses.
Layer by layer calculations are currently restricted to axial flow exchangers.
Stream by stream calculations can be used for axial and crossflow
exchangers. Layer by layer calculations can take significantly longer than
stream by stream calculations, particularly for exchangers with a large
number of layers.
First Shot Design: These calculations provide an initial estimate of the size of
exchanger(s) needed to perform a specified duty. They predict the number of
layers for each stream and the size of all layers, together with the finning to
be used in each, and distributor and header locations and dimensions. They
do not determine a layer pattern. The term "first shot" is used because an
experienced designer may well be able to significantly improve the design,
and because (unless proprietary fin performance data is used) a manufacturer
will almost certainly produce a different design for the duty.
Design calculations are restricted to axial flow exchangers. They cannot be
used for crossflow exchangers at present.
No geometry information is needed for a Design calculation, but any that is
provided will be incorporated when possible. This could for example include
specification of some or all of the fins to be used.
Design calculations are based on the common stream temperature
assumption.
See Also:
Area Ratio and Checking
 PlateFin: Exchanger Type
You can specify various exchanger types:
• Standard axial flow: All streams are in co- or counter-current axial flow,
normally with the hot streams flowing down and the cold streams flowing up.
This exchanger type applies to most large brazed aluminum exchangers used
for cryogenic applications.
• Simple crossflow: This applies to two-stream exchangers, in which one
stream flow vertically (up or down) while the other stream flows horizontally.
There are no distributors, and stream headers cover the entire ends (or sides)
of the exchanger. This exchanger type often applies to steel (or other metal)
exchangers used for gas-gas applications at room temperature or above. They
are used for other applications as well, and there is no restriction of the
applications which can be modeled.
• Multi-pass crossflow: This applies to crossflow exchangers with one (or
more) axial flow stream and one (or more) crossflow stream, each flowing in
one or more crossflow passes. Axial flow streams may optionally have
distributors. These exchangers are at present restricted to cases where
multiple passes for any stream are in series in the same layer
• Plate-fin kettles: These are kettle reboilers, in which a crossflow plate-fin
exchanger is used instead on a tube bundle. The parting sheets are vertical.
The cold stream has vertical fins, open at the top and bottom to permit boiling
in upflow, and return of unvaporized liquid to the pool in which the exchanger
is immersed. The hot (condensing) stream flows horizontally. The exchanger
is defined as being horizontal, with the condensing stream inlet at end A. The
condensing stream has distributors. The program calculates the flowrate of
the internal recirculation, and overall stream outlet conditions.
Standard axial flow exchangers are modeled along one main dimension,
the exchanger length. They usually have an end-to-end temperature
difference which is much larger than the typical local hot to cold stream
temperature difference.
Crossflow exchangers are modeled in two dimensions, along and across the
layers. Stream temperature changes are often relatively small. Hot to cold
stream temperature differences can sometimes be very small in one corner of
the exchanger, but elsewhere are often relatively large.
Axial flow exchangers should have most streams in axial flow. It is
permissible for them to have a stream in multipass crossflow – zig-zagging up
the exchanger, in a large number of cross-flow passes, or to have a stream in
single pass crossflow occupying only a small fraction of the exchanger length.
Temperature differences are modeled as if the stream were in axial flow, but
using the correct crossflow dimensions to give mass fluxes for calculating heat
transfer and pressure drop.

For all the three crossflow exchanger types, stream-by- stream Simulation
(using the common wall temperature assumption) is the only available
calculation mode. Layer by layer simulation, and Design options are not
available.

See also:
Specifying Crossflow Exchangers
 PlateFin: Number of Streams
You must specify the number of process streams in the exchanger.
Up to 20 process streams can be specified.
 PlateFin: Number of Fins
You may find it helpful to explicitly specify the number of types of fin used in
the exchanger. This should include main fins, distributor fins and hardway fins
if any.
Fins are normally numbered 1, 2, 3 etc, although reference can be made to
fins in a data bank which have numbers in the hundreds or thousands.
If omitted, the program will simply count the number of different types of fin
you have specified for the various layer types and their distributors.
 PlateFin: Number of Layer Types
You should indicate the number of different types of layer in the exchanger.
Layer types are the basis on which exchanger geometry is specified. Layers
types are designated A, B, C, D etc. This permits the layer pattern (stacking
pattern) to be specified as a sequence of letters. In stream by stream
simulation, if you do not specify a layer pattern, you will need to explicitly
specify the number of layers of each type.
You may include layer types which contain no streams but are used for
instrumentation.
Layer type input is not used in Design Mode.
 PlateFin: Number of Thermosiphon Streams
A thermosiphon stream is the cold stream in a thermosiphon reboiler. At
present there can be at most one such stream.
Thermosiphons can be external (connected to the column by pipework) or
internal (immersed in a column sump). No pipework is needed for internal
reboilers.
For a thermosiphon reboiler, in addition to this input, you need to identify the
stream type for one stream as thermosiphon in the Process Options section
of input.
 PlateFin: Number of Distributor Types
The number of distributor types is usually the same as the number of
streams. If there are N streams, then Distributors 1-N relate to streams 1-N
respectively. There can be situations, however, where a stream has different
distributor geometries in different layer types, which means it is necessary to
specify two (or more) inlet and two (or more) outlet distributors for a stream.
One set of inlet/outlet distributors will have the same number as the stream
number, other sets must have numbers above N.
If you have an exchanger with this type of complexity, specify a number of
distributor types which is greater than the number of streams.
Note that this number only applies to main inlet and outlet distributors.
Redistributors and intermediate distributors can be allocated numbers
different from their stream number, so there should be no problem specifying
multiple such distributors for a single stream, should this be necessary.
 PlateFin: Common Wall Temperature
Assumption
The common wall temperature assumption is used for stream-by-stream
simulations.
It assumes that all the layers of a given type behave identically, and that, at
any point along the exchanger, all the parting sheets (separating plates
between layers) have the same temperature.
For common wall temperature calculation the program uses only the number
of layers of each stream, not the order in which they are arranged (the layer
pattern or stacking pattern). It is effectively assumed that there is a “good”
layer pattern, meeting the objective of minimal temperature variation
through the depth of the exchanger.
In order to determine how good a layer pattern is, full layer by layer
calculations should be performed.
 PlateFin: Common Stream Temperature
Assumption
The common stream temperature assumption is that not only do all the layers
of a given stream behave identically, but that at any point along the
exchanger, all the hot streams are at one temperature and all the cold stream
are at one temperature. There is thus one temperature profile along the
exchanger for all hot streams, and one for all cold streams, rather than there
being a separate profile for each stream (as in the common wall temperature
assumption) or one for each layer.
The common stream temperature assumption is justified in that it is a design
objective. Heat transfer is most efficient when all the hot streams are at the
same temperature and all the cold streams are at the same temperature.
Temperature uniformity also reduces thermal stresses. In reality, at any point
along the exchanger, each stream may be slightly above or slightly below the
average for its type (hot or cold).
 PlateFin: Checking and Simulation
There are two calculation modes which are rating modes, Checking and
Simulation. Strictly, these might be termed Heat Load Checking and Heat
Load Simulation. Their definition for multi-stream exchangers is more subtle
than for two-stream exchangers.
See Checking and Simulation, Heat Load
By analogy, it is possible to define Pressure Checking or Pressure Simulation,
among other options, when calculating the pressure of each stream.
See Checking and Simulation, Pressure
None of the above applies to Design mode, which uses an entirely separate
calculation method.
 PlateFin: Checking and Simulation, Heat Load
Heat Load Simulation involves calculating the heat load of each stream, and
in its most common form, involves calculating the stream outlet conditions for
fixed inlet conditions. Variants such as calculating the stream inlet conditions
for a fixed outlet are also available but should be used with care.
Heat Load Checking involves calculating a scaling factor so that if the
calculated heat transfer were divided by this factor, the specified heat load
would be achieved. Conventionally, for two stream exchangers, this scaling
factor is the same for both streams and is referred to as the area ratio, the
ratio of actual to required area. Values above unity indicate that the
exchanger will exceed the required duty, but offer little quantitative insight
into by how much.
For Heat Load Checking in multi-stream exchangers, a separate scaling factor
is calculated for each stream. While values above unity are broadly good, for
these exchangers, they are of less direct use than for two-stream exchangers.
There is no guarantee that the notional excess of actual over required area
will be in the part of the exchanger where it is most needed, particularly
when streams enter and leave at different points along the exchanger length.
Heat Load Checking or Simulation is a single option selected for the entire
exchanger. Checking has not previously been available in EDR software for
plate-fin exchangers. It is provided because it is already in the standard E DR
solution procedures used, and because it provides an option which may be
useful if Simulation calculations encounter convergence difficulties.
Heat Load Checking is only available for stream-by-stream calculations. Heat
Load Simulation can be done on either a stream-by-stream or layer-by-layer
calculation.

See also:
Checking and Simulation
 PlateFin: Checking and Simulation, Pressure
Although the terms Checking and Simulation normally refer to heat loads, it
is also possible by analogy to define Checking and Simulation for pressure
calculations. Conventionally pressure calculations involve Pressure
Simulation, usually calculation of outlet pressures for a specified inlet.
Pressure Checking involves keeping the inlet and outlet pressures fixed and
calculating a scaling factor, which if applied to the calculated pressure change,
would give consistency with the specified inlet and outlet pressures. The
pressure at any point within the exchanger is found using the inlet pressure
and the scaled pressure change to that point. There is a further form of
pressure calculation which involves Simulation as long as the outlet pressure
does not fall below a specified minimum pressure, but reverts to Checking,
using the inlet and the specified minimum, for higher predicted pressure
changes. This is the default option, since it is “safe” in preventing implausibly
low pressures, and concomitant calculation instabilities. When this occurs
there is a warning that scaled pressure changes have been used to determine
pressures.
Explicit specification of the minimum pressure was introduced in V7.3.2.0.
Prior to that the minimum used for this purpose was effectively the inlet
pressure less the maximum allowed pressure drop. The default for minimum
is such that warnings about scaled pressure changes will occur less
frequently. Pressure Checking or Simulation, and other related options, are
available individually for each stream, and each can be used in conjunction
with either a Heat Load Simulation or Heat Load Checking Mode.
See also:
Checking and Simulation
 PlateFin: Process Data
The Process Data section includes the following screens:
Process
Process Options
Partial Draw-off
Process data are the most important: here, you can specify inlet and outlet
conditions - some or all of pressure, temperature, specific enthalpy, quality.
According to the calculation, some of these will be fixed, others will be initial
estimates.
Process Options includes other process-related parameters for each stream.
Many have default values, but you should check these are acceptable. Process
Options is also where you identify which stream is a thermosiphon stream.
See Also:
Process Data Cross-Checking
 PlateFin: Process
The Process screen includes the following inputs:
Stream Name
Total Mass Flow Rate
Inlet Temperature
Outlet Temperature
Inlet Quality (vapor mass fraction)
Outlet Quality (vapor mass fraction)
Inlet Pressure
Outlet Pressure
Inlet Specific Enthalpy
Outlet Specific Enthalpy
Allowed Pressure Drop
Estimated Pressure Loss
Heat Load
Fraction of Maximum Heat Load
Adjust if overspecified
Fouling Resistance
Pressure at Liquid Surface (Thermosiphon)
To begin its calculations, the program always needs an initial set of input and
outlet conditions and heat loads which are in balance over all streams,
making allowance for any additional external heat load into or out of the
exchanger. A consistency check is performed on the initial data. Input values
may be changed slightly, and a warning issued if an inconsistency is found.
The process screen lets you specify the inlet and outlet conditions for each
process stream. Conditions include pressure, temperature, specific enthalpy,
and quality (vapor mass fraction). It is adequate to specify just the pressure
and specific enthalpy at the two points, since temperature and quality can
then be calculated by interpolation of the properties data. However, specifying
pressure and either temperature or quality might be a more convenient
alternative. You may overspecify the data at each point (inlet and outlet). If
you do so, a consistency check will be performed, and the temperature or
quality will be revised if necessary, and a warning message issued.
If data at all are provided at only inlet or only outlet conditions, the program
will use information from the stream heat load and mass flowrate to
determine the specific enthalpy and other conditions at the other of the two
points. If both inlet and outlet conditions and mass flow rate are known, then
the heat load for the stream can be calculated. If the heat load of all but one
stream is known, a heat balance is used to determine the heat load of that
stream.
For Design and Checking calculations, you must specify, implicitly or
explicitly, both inlet and outlet conditions for each stream. For simulation
calculations, some conditions, usually outlet, will be an initial estimate.
Specifying a reasonably good initial estimate can help improve calculation
stability in difficult cases.
Stream heat load (in the absence of partial draw-off) is the stream mass
flowrate times the difference in specific enthalpy between inlet and outlet.
Specifying any three of these four parameters means the fourth can be
calculated.
If you provide inadequate information on outlet conditions, the program will
attempt to set up initial estimates. One estimation method involves setting an
initial heat load for each stream which is some fraction of its maximum
possible heat load. For complex, multi-stream exchangers, these may not be
very good estimates and will sometimes lead to computational instability.
In general, if you are able to supply a flow rate and an inlet and outlet
temperature for each stream, actual or a good estimate, you should do so.
 PlateFin: Stream Name
You can enter a Stream name to help you relate stream number to process
fluids. The name is repeated on various other pages of input or output. When
data are imported from Process Simulators, names from the simulator should
be picked up automatically.
 PlateFin: Total Mass Flow Rate
Specify the total mass flow rate of the stream. If there is more than one
exchanger in parallel, specify the total flow through all the exchangers.
In most calculation modes, the stream flowrate is fixed. If, however, the
stream flowrate is to be calculated – for example in a thermosiphon reboiler -
you must still supply an initial estimate.

See also:
Process
 PlateFin: Inlet Temperature
Specify the stream temperature at inlet to the exchanger. You should either
input the temperature directly or input a specific enthalpy or quality from
which it can be calculated.
In most calculation modes, the stream inlet temperature is fixed. If it is to be
calculated, you should still supply an initial estimate.
For thermosiphon reboilers, this inlet temperature may be recalculated, based
on the calculated stream inlet pressure and the stream specific enthalpy at
inlet to the exchanger, which is assumed to be the same as the bubble point
enthalpy at the liquid surface in the vessel (column sump) feeding the
thermosiphon.

See also:
Process
 PlateFin: Outlet Temperature
Specify the stream temperature at the main outlet from the exchanger. You
should either input the temperature directly or input a specific enthalpy or
quality from which it can be calculated.
In most simulation modes, the stream outlet temperature is calculated, so
what you supply will be taken as an initial estimate.

See also:
Process
 PlateFin: Inlet Quality (vapour mass fraction)
Specify the stream vapor mass fraction at inlet to the exchanger. You should
either input this directly or input a specific enthalpy or temperature from
which it can be calculated.
Vapor mass fractions are important for streams which are boiling or
condensing isothermally, where temperature alone is not adequate to define
the stream conditions.
When a vapor mass fraction of zero or unity is specified, without any
accompanying temperature or specific enthalpy information, it is assumed to
relate to the bubble or dew point.

See also:
Process
 PlateFin: Outlet Quality (vapour mass fraction)
Specify the stream vapor mass fraction at outlet from the exchanger. You
should either input this directly, or input a specific enthalpy or temperature
from which it can be calculated.
Vapor mass fractions are important for streams which are boiling or
condensing isothermally, where temperature alone is not adequate to define
the stream conditions.
When a vapor mass fraction of zero or unity is specified, without any
accompanying temperature or specific enthalpy information, it is assumed to
relate to the bubble or dew point.

See also:
Process
 PlateFin: Inlet Pressure
You must specify the stream inlet pressure. If this pressure will be determined
during the calculation, an initial estimate must be given.

See also:
Process
 PlateFin: Outlet Pressure
You can specify the stream outlet pressure. If this pressure will be determined
during the calculation, an initial estimate can be given. If you are calculating
the exchanger inlet pressure from a fixed outlet, it is important to make sure
that the outlet pressure value is what you want.
If omitted, a default value will be determined using the inlet pressure and the
estimated pressure drop. Explicitly specifying the exchanger outlet pressure
can be useful when gravitational effects are significant.

See also:
Process
 PlateFin: Inlet Specific Enthalpy
You can input the specific enthalpy of the stream at inlet to the exchanger.
Specific Enthalpy is a preferred input if it is available and if you have provided
consistent specific enthalpy and pressure information in the properties data
for the stream.
If it is not available or of questionable reliability, omit the specific enthalpy
and supply the inlet temperature instead.

See also:
Process
 PlateFin: Outlet Specific Enthalpy
You can input the specific enthalpy of the stream at exit from the exchanger.
Specific Enthalpy is a preferred input if it is available and if you have provided
consistent specific enthalpy and pressure information in the properties data
for the stream.
If it is not available or of questionable reliability, omit the specific enthalpy
and supply the outlet temperature instead. The program will calculate the
corresponding specific enthalpy.
In most simulation modes, the stream outlet conditions are calculated, so
what you supply will be taken as an initial estimate.

See also:
Process
 PlateFin: Allowed Pressure Drop
Enter the maximum permitted pressure drop in the exchanger. For Design
calculations, this is the maximum permitted frictional loss and does not
include any gravitational changes. For Simulation calculations, this parameter
only affects the results if the calculated pressure drop exceeds the specified
value. In some pressure calculation modes, pressure calculations will switch to
Pressure Checking at this limit so that even if a large pressure drop is
predicted, the exchanger outlet pressure does not fall below the
corresponding limit value.
 PlateFin: Estimated Pressure Loss
Enter the estimated pressure decrease in the exchanger. This is the difference
between the inlet and outlet pressures in the exchanger. If you select
Pressure Checking as the pressure calculation option for this stream, then the
pressure change in the exchanger will be reported at a multiple of this
parameter, while the inlet and outlet pressures in the exchanger remain set
at their initial values.
 PlateFin: Heat Load
You can specify the stream heat load. In Simulation calculations, heat loads
are calculated, so any value you supply here is an initial estimate.
Stream heat load (in the absence of partial draw-off) is the stream mass
flowrate times the difference in specific enthalpy between inlet and outlet.
Specifying any three of these four parameters means the fourth can be
calculated.

See also:
Process
 PlateFin: Adjust if overspecified

To begin its calculations, the program always needs an initial set of inlet and
outlet conditions and heat loads which are in balance over all streams –
making allowance for any additional external heat load into or out of the
exchanger. A consistency check is performed on the initial data. Input values
may be changed slightly, and a warning issued if an inconsistency is found.
Adjust if overspecified lets you prioritize whether inlet conditions, outlet
conditions, or flowrate should be modified. Simulation calculations normally
involve calculation of outlet conditions, so by default it is normally the initial
value of outlet conditions (temperature) which is identified as changeable, if
any modifications are necessary.

See also:
Process
Process Data Cross-Checking
 PlateFin: Fouling Resistance
You may specify a fouling resistance for each stream. This is a resistance
based on full local heat transfer area and assumed to apply throughout the
exchanger and on both primary and secondary surfaces. On the fins, it is used
to determine the overall local heat transfer coefficient used to calculate fin
efficiency.
In cryogenic equipment, the fluids are normally clean and non-corrosive, so it
is common for fouling resistances to be set to zero.
 PlateFin: Process Options
The Process Options screen includes the following inputs:
Stream Name
Stream Type
Flow Direction
Design Pressure
Simulation Revision Option
Pressure Calculation Option
Minimum Calculated Pressure
Solution Method
There will usually be defaults set for all these input, but you should check
these are appropriate.
For a thermosiphon stream, you must specify the stream type appropriately.
 PlateFin: Stream Type
With this input item, you can identify whether the stream is hot or cold.
Normally this will be obvious from the specified inlet and outlet temperatures,
and the correct default will be set. If, however, you have elected to omit the
stream outlet temperature and there are more than two streams, then you
should check that the default for this input item is correct and set it explicitly.
There is also a third option: specify that the (cold) stream is a thermosiphon
stream. This option must be selected to give access to all the other data input
for thermosiphons.
Only one stream can be identified as a thermosiphon.
You might need to reset this item for isothermally boiling streams which exit
at a lower temperature than inlet, because of pressure changes and can
default to hot rather than cold.
 PlateFin: Flow Direction
With this input item, you can specify the stream flow direction. A correct
default should normally be set for axial flow stream, based on hot streams
flowing downwards, and cold streams flowing upwards. You should check that
any default is correct, and reset it if necessary.
 PlateFin: Design Pressure
Specify a Design pressure for the stream. This primarily required in Design
mode. An estimated default value will be set up from process conditions, but if
a value is available, you should input it.
Higher Design pressures imply higher fin thicknesses, as well as increased
thicknesses and smaller dimensions for other stream components. If one
process stream needs thicker fins, then the thickness of fins for other streams
will need to be increased, even if the design pressure of these streams is
relatively low.
 PlateFin: Simulation Revision Option
Simulation calculations normally determine stream outlet conditions
(temperature).
Other options of inlet temperature and flow rate are available, but should be
used with care as they can lead to convergence problems. Attempting to
calculate the inlet temperature of more than one stream can create a problem
without a well defined solution.
 PlateFin: Pressure Calculation Option
The two main options available are
· Predict Outlet Pressure
· Predict Outlet Pressure, subject to a specified minimum pressure
In order to determine pressures along the exchanger, pressure changes to all
points along the exchanger (friction losses as well as gravitational and
accelerational changes) are first calculated. These are then used to calculate
the actual pressure at each point, assuming the inlet pressure is fixed and
working towards the calculated outlet pressure. It is, however, possible that
the calculated pressure changes will be much larger than anticipated, possibly
even larger than the inlet pressure. For gases, large pressure changes give
reduced densities which in turn give even larger pressure changes.
In a real exchanger, this would imply choked flow, but when running the
program, it can arise from an error in the specified flow rate or an error in the
specified geometry giving too low a flow area.
The second of the above options, the default, helps prevent this run-away
situation by imposing a minimum calculated outlet pressure. If necessary,
calculated pressure changes are scaled before being used to calculate local
pressures, to ensure that the outlet pressure never falls below a minimum
pressure which you can specify. With the first option, there can also be a
program imposed scaling but only as a safety mechanism to prevent negative
pressures. Whenever pressures derive from scaled pressure changes, a
warning message is produced.
The three other calculation options are
· Predict Inlet pressure
· Predict Inlet Pressure, subject to a specified minimum pressure
· Pressure Checking
Predicting the Inlet pressure to achieve a specified outlet pressure can
sometimes be useful. The option of imposing a minimum pressure is unlikely
to be needed, but is include for completeness.
Checking a pressure means assuming that the inlet and outlet pressure are as
specified in the input and reporting the multiplier by which the calculated
pressure drop would need to be multiplied to achieve the specified inlet to
outlet pressure change.
If you do elect the option of simply calculating an outlet pressure, the
program will prevent subzero pressures being predicted, but will still permit
very low pressures to be predicted. Pressure drops themselves increase when
gas densities are very low, so when a pressure drop problem occurs, it is easy
for it to generate a run-away situation where extremely high pressure losses
are predicted.

See also:
Checking and Simulation, Pressure
 PlateFin: Minimum Calculated Pressure
This input is to assist with cases where the calculated pressure drop is much
higher than anticipated. In extreme cases the pressure drop might even be
predicted to be bigger than the stream inlet pressure. The program handles
such cases by applying a scaling factor to the calculated pressure changes
before using them to calculate absolute pressures. The scaling is calculated,
when needed, by ensuring that calculated outlet pressure does not fall below
the specified minimum.
When this type of pressure change scaling is applied, a warning message is
produced.
The default value of the minimum calculated pressure is typically three
quarters of the inlet pressure, unless you have explicitly specified an outlet
pressure or a maximum pressure drop, indicating that a lower default
minimum is required.
In versions of the program prior to V7.3, the minimum calculated pressure
was not an explicit input, but was always taken to be the inlet pressure less
the maximum pressure drop. This new input item both gives you more control
on calculated pressure changes and will mean that the warning about
pressure scaling will occur less frequently.

See also:
Pressure Calculation Option
 PlateFin: Solution Method
The standard calculation procedure in Simulation involves updating the
enthalpy profile of each stream along the exchanger, using an integral of the
heat transfer coefficient and driving temperature difference for the stream.
The relaxation parameter determines the weightings of the integral, and the
old profile is used to calculate the new profile.
This method works well, except for streams with a very low flowrate. Since
these streams can only gain or lose very small amounts of heat, they will
have a temperature very close to the local wall temperature. If they enter at
a temperature different from the wall, they will adjust to the wall temperature
in a very short distance. As the solution is approached, however, the
temperature of such streams can differ significantly from the wall
temperature, and their predicted heat load can be many times greater than
they can achieve. They can thus be predicted to have temperatures very
different from that appropriate to their location in the exchanger. This can
lead to calculational instability for the entire exchanger.
For this reason, a separate solution method is used for low flow streams,
which involves updating their enthalpy profile based on their response to the
calculated wall temperature. This stepwise calculation updates the enthalpy
profile as it integrates, rather than doing a complete integration, and then a
complete update. The strength of the low-flow method is that it always
predicts stream temperatures close to the local wall temperature, matching
physical reality. The downside is that does not incorporate an automatic heat
balance as the calculation proceeds, though the final solution should have a
heat balance.
The default for this input item is to let the program decide which is a low-flow
stream, and which is a standard stream. However, it is possible explicitly to
set the method as Standard or Low-flow for any stream. This can
sometimes help achieve convergence.
The option Design appears in the drop down list and is the automatic default
(and only permissible option) in Design mode, which uses an entirely separate
calculation procedure.
The final option Standard (variant) should not be used unless explicitly
advised by Support.
 PlateFin: Partial Draw-off
The Partial Draw-off screen includes the following inputs:
Draw-off from Stream
Draw-off Fraction
Draw-off Temperature
Draw-off Quality
Draw-off Pressure
Draw-off Specific Enthalpy
With partial-draw-off, you specify that part of a stream is drawn-off at some
point along the exchanger, while the remainder of the stream continues to
the main outlet header. The option is only available for axial flow exchangers.
This screen provides the process data input relating to partial draw-off. A
redistributor, which directs the flow to the draw-off header, should be
specified in the Layer Type input.
Multiple partial draw-offs are possible in principle. For such cases, the draw-
offs are identified by draw-off numbers. The draw-off number must be
specified for the header relating to the redistributor, in the Special
Distributors input.
When there are multiple draw-offs for a single stream, you should specify
these in flow sequence for the stream and not mix them up with any draw-off
points for other streams.
 PlateFin: Draw-off from Stream
Identify the stream with partial draw-off.

See also:
Partial Draw-off
 PlateFin: Draw-off Fraction
Input the fraction of the initial stream input drawn-off at this point.

See also:
Partial Draw-off
 PlateFin: Draw-off Temperature
Specify the temperature at which partial draw-off occurs.

See also:
Partial Draw-off
 PlateFin: Draw-off Quality
Specify the quality (vapor mass fraction) at which partial draw-off occurs.

See also:
Partial Draw-off
 PlateFin: Draw-off Pressure
Specify the actual or estimated pressure at which partial draw-off occurs.

See also:
Partial Draw-off
 PlateFin: Draw-off Specific Enthalpy
Specify the specific enthalpy at which partial draw-off occurs. If omitted, a
value will be calculated from a specified draw-off temperature and pressure.

See also:
Partial Draw-off
 PlateFin: Exchanger Geometry
The Exchanger Geometry section includes the following sections:
General
Layer Types
Distributors
Exchanger Diagram
Fins
Fin Performance
Thermosiphons
Pipework

In Simulation or Checking mode, the exchanger geometry must be specified.

The key information needed is under Geometry, Layer Types, Distributors and
Fins. The Exchanger Diagram is generated automatically after adequate
information is provided.
In Design mode, no geometry information is needed; however, you can
specify some geometry items and let the program predict the remainder.
 PlateFin: General
The General section includes the following screens:
General
Layer Pattern
PlateFin Kettles
The most important information you need to provide is the exchanger width
(on the General screen) and either the layer pattern or the number of layers
of each type.

Together with further input on layer types and distributors, the program can
then generate the
Exchanger Diagram
 PlateFin: General
The General screen includes the following inputs:
Number of Exchangers in Parallel
Number of Exchangers per Unit
Orientation
Exchanger Metal
Exchanger (core) Length
Exchanger (core) Width
Exchanger (core) Depth (stack height)
Side Bar Width
Internal (effective) Width
Parting Sheet Thickness
Cap Sheet Thickness
Number of X-flow Passes
Number of Layer Groups
For Simulation or Checking, you must specify either the Exchanger Width
(external) or the Internal Width. The other items have defaults. The default
length can be set from Layer Type information, but if you set it here, it
provides a useful cross-check. Other defaults should be reset if they are not
appropriate.
 PlateFin: Number of Exchangers in Parallel
Specify the number of exchanger cores in parallel. A set of cores is sometimes
brazed together into a unit with common stream headers spanning the set of
cores. In such cases, the number of exchangers in parallel is the product of
the number of exchangers per unit and the number of such units in parallel.
In Design mode, this item may be omitted, leaving the Design algorithm to
select an appropriate number.
 PlateFin: Number of Exchangers per Unit
A unit is a set of exchanger cores welded together so that stream headers can
each span the entire set while a single nozzle can feed each header.
Grouping exchangers together in this way affects the nozzle pressure loss but
not any other part of the calculation.
 PlateFin: Orientation
Plate fin exchangers are normally vertical, with upflow and downflow and the
hot end at the top. The ends of the exchanger are designated A and B, with
end A at the top.
Occasionally exchangers are horizontal with horizontal flow. In this case, the
plate fin layers can be either horizontal or vertical, so you need to specify
which. This will usually affect the calculated results only insofar as it affects
gravitational pressure changes in the headers.
 PlateFin: Exchanger Metal
The large plate fin exchangers for cryogenic applications are almost always
brazed aluminum, but other metals can be used for other smaller exchangers
used for applications at ambient or higher temperatures.
The exchanger metal is important primarily for the fins: the fin efficiency is
reduced for low metal conductivities, particularly for long or thin fins. There is
a secondary effect in conduction through the parting sheets and in
longitudinal conduction along the exchanger length.
 PlateFin: Exchanger (core) Length
Enter the full external length of the plate fin exchanger core. This does not
include any allowance for headers and stubs/nozzles welded on to the core.
This length is the length of each layer, measured in the axial direction, and is
used as a check on the total length a specification of all the items within each
layer type.
 PlateFin: Exchanger (core) Width
Enter the full external width of the plate fin exchanger core. This does not
include any allowance for headers and stubs/nozzles welded on to the core.
This width is the width of each layer, measured transversely to the axial
(flow) direction and is the same for each layer type.
 PlateFin: Exchanger (core) Depth (stack height)
The exchanger depth (stack height) is the third dimension, alongside the
exchanger width and length, that defines the rectangular core of the
exchanger.
The stack height is the sum of the thicknesses of every layer (fin height plus
parting sheet) plus the thickness of the cap sheets. The term stack height
applies to the orientation of the exchanger during construction, when layers
laid horizontally on top of each other prior to brazing, rather than during
operation when the layers are normally vertical.
 PlateFin: Side Bar Width
Enter the width of a side bar. These are assumed to be the same in all layers.
The effective width for axial flow along the exchanger is the (full) exchanger
(core) width, less two sidebar widths.
 PlateFin: Internal (effective) Width
Enter the internal (effective) width for axial flow along the exchanger. This is
the (full) exchanger (core) width less two sidebar widths, and it is assumed to
be the same in all layers of the exchanger.
In Design mode, this item is normally calculated, rather than specified.
However, if it is specified, it will be used in the Design.
 PlateFin: Parting Sheet Thickness
Enter the thickness of the parting sheets (separating plates). The plate fin
exchange is made up layers formed alternating finning, through which the
fluid flows, and parting sheets which separate the streams in adjacent layers.
Fin heights can differ in different layers, but all parting sheets in the
exchanger are assumed to have the same thickness.
 PlateFin: Cap Sheet Thickness
On the outside of the plate fin core, Cap Sheets are used, which are thicker
than the parting sheets which separate layers internally. Enter the thickness
of these cap sheets.
 PlateFin: Number of X-flow Passes
Enter the number of crossflow passes for a crossflow exchanger.
A maximum of one crossflow pass is permitted for Simple Crossflow and Plate-
fin Kettles.
This item refers to the exchanger as a whole. It is not used for axial flow
exchangers, where one dimensional modeling (axially along the exchanger) is
for each stream or layer – even if some streams are in multi-pass cross
counterflow or flow in a short crossflow pass somewhere along the exchanger.
 PlateFin: Number of Layer Groups
This input will be available in future releases of PlateFin.
This item is for crossflow exchangers which have multiple crossflow passes,
using layers in different parts of the stack, rather than multiple passes in a
single layer.
The various parts of the stack are referred to as the Layer group. Each layer
type must have the group in which it occurs identified. An example might be
an exchanger with a layer pattern
ABABAB..ABAB CDCDCD..CDCD EFEFEF EFEFE
One stream might flow through layers A, C, E in parallel, another through
layers B, D, F in series. Such an exchanger would have three layer groups.
Each layer type would be very simple, comprising a single axial pass or a
single crossflow pass. It is likely that layers A, C, and E in such a case would
be physically identical, but nevertheless three different each layer types need
to be specified, one for each layer group.
 PlateFin: Layer Pattern
The Layer Pattern screen includes the following inputs:
Layer Pattern
Layer Pattern Symmetry
Number of Layers
Fraction Double Banked
The Layer Pattern and its Symmetry flag are mandatory in Layer by Layer
Simulation. For Stream by Stream Simulation or Checking, these are
optional, but if omitted you must input the number of layers of each layer
type.
 PlateFin: Layer Pattern input
The layer pattern must be input when you are doing layer by layer
calculations. For stream by stream calculations with the common wall
temperature (CWT) assumption, the layer pattern in optional. In such cases,
it is simply used to determine the number of layers of each type.
The Layer pattern is not used in Design mode.
The layer pattern or stacking pattern in an exchanger defines the sequence of
layer types within the exchanger. In its simplest form, it is a sequence of
characters, for example ABACDABACAEAD…..indicating that the first layer,
adjacent to the cap sheet, is layer type A, the next layer type B, the next
another layer of type B and so on.
You should normally specify the entire layer pattern, the one exception being
layers with central symmetry, for which only the left hand half of the pattern
need be specified. The last (rightmost) layer type specified is the one in the
center of the exchanger (or the one immediately prior to the central parting
sheet, if there are an even number of layers).
Layer patterns are often constructed from repeated subsets of layers. A
simplified way of inputting the pattern makes use of this feature. For
example, a specification such as
AB(ADAC*4) means AB ADAC ADAC ADAC ADAC. The repeated element is in
brackets, with a * followed by a one or two digit integer indicating the
number of times the sub-pattern is repeated. This only affects the way the
pattern is specified. A subsequent layer by layer calculation will still allow for
all the layers in the pattern in its extended form.
Spaces in the pattern are ignored – with the exception that within brackets
there should not be spaces around the * or repeat counter. Putting spaces in
the pattern can make the pattern easier to read and check.
If you specify both the layer pattern and the number of layers of each pass
these are cross-checked against each other. Inputting both is recommended,
as it is easy to make mistakes typing in a long sequence of characters.
 PlateFin: Layer Pattern Symmetry
When you have a symmetric pattern, you only need to
· Enter the left-hand half of the pattern
· Set a flag to indicate symmetry, in particular whether the last
(rightmost) layer type specified represents:
– The central layer when there are an odd number of layers, or
– The layer type immediately preceding the central parting sheet for
an even number of layers
If the pattern is not symmetric, this flag indicates that the entire pattern has
been input.
With symmetry, the calculation is performed for half of the exchanger only,
with appropriate boundary conditions at the center, depending on the type of
symmetry.
 PlateFin: Number of Layers
For each layer type, you can specify the number of layers of that type in one
exchanger. In Simulation and Checking modes, these inputs are mandatory if
you do not specify a layer pattern. If you do specify a pattern they are
optional, but specifying the number of layers of each type is recommended to
give a consistency check with the pattern.
If the exchanger has central symmetry and you only specify a half pattern,
you still specify the total number of layers of each type in one exchanger,
which will normally be twice the number of times the layer type appears in
the pattern.
In Design mode, the layer types cannot be specified, so this input is
irrelevant. There is, however, a separate input, PlateFin Number of layers
(Design) under Design Options, Stream Design. With this you can optionally
specify the number of layers for any stream, leaving the program to design
any unspecified values.
 PlateFin: Fraction Double Banked
Double banking occurs when two adjacent layers of the same stream appear
in a layer pattern, for example B in the pattern ABBABBABBA. This input lets
you specify the fraction of layers of a given type which are double banked. In
this example, the fraction for B is 1.0. In the pattern ABABBABA, the fraction
for B is 0.5, since two of the four layers are double banked.
Double banking also occurs whenever two hot stream layers or two cold
stream layers occur together. For example if A is hot, and B and C are cold in
the pattern ABCACBABCA, then both B and C have a double banking fraction
of 1.0.
If you specify a layer pattern, this input is not needed since the program can
work it out from the pattern, but default values will show you the double
banking fractions calculated from the pattern. Note that the first and last
layers in a pattern are effectively double banked, since they have a layer of a
different type on one side only. Thus in the two short patterns above, the
double banking fraction of layer A is 0.5, since two of the four layers are
outer layers.
The double banking fraction is not used in layer by layer calculations, so this
input is ignored. It can however improve the accuracy of stream by stream
(common wall temperature) calculations.
If you do not specify the layer pattern, the double banking fraction is
estimated from the layer count. This should be reasonably accurate when
there are the same number of hot and cold layers (nearly all single banked)
or there is a hot to cold layer ratio close to 2.0 or 0.5, when nearly all the
layers of one type will be double banked. In other cases, with the exception of
the trivial two stream case, the estimated defaults may be very approximate.
 PlateFin: PlateFin Kettles
The Plate-fin Kettles screen includes the following inputs:
Kettle Inside Diameter
Exchanger Height above bottom of Kettle
Liquid Height above bottom of Kettle
Number of Nozzles on Kettle

These inputs are required when the Exchanger Type is a Plate-fin Kettle.
Note that the program primarily models the plate fin core within the kettle,
rather than the entire kettle. Exchanger inlet and outlet conditions reported
in the output relate to the plate-fin exchanger itself, not the entire kettle. The
recirculating boiling flow within the plate-fin exchanger will usually be
significantly higher than the liquid feed to the kettle and will be determined
by the program.
 PlateFin: Kettle Inside Diameter
Plate-fin Kettles are crossflow exchangers inside a horizontal tubular vessel
known as a kettle. The kettle is partially full of liquid in which the exchanger
is immersed. There is a vapor space above the exchanger to accommodate the
vapor generated when the liquid is boiled.
Specifying the diameter for the kettle does not affect the exchanger
performance, but it permits calculation of the size of the vapor space and
estimation of the risk of entrainment of liquid droplets in the outgoing vapor.
See also:
Plate-fin Kettles
 PlateFin: Exchanger Height above bottom of
Kettle
For a plate-fin kettle, you must specify the height of the bottom of the
exchanger above the bottom of the kettle, and the height of the liquid surface
above the bottom of the kettle.
The absolute values of these parameters are of secondary importance, but
they should be broadly consistent with the specified kettle internal diameter.
The difference between the two values is fundamental, since this determines
the head of liquid providing the pressure driving the boiling flow through the
plate-fin exchanger inside the kettle.
See also:
Plate-fin Kettles
 PlateFin: Liquid Height above bottom of Kettle
For a plate-fin Kettle, you must specify the height of the bottom of the
exchanger above the bottom of the kettle, and the height of the liquid surface
above the bottom of the kettle.
The absolute values of these parameters are of secondary importance, but
they should be broadly consistent with the specified kettle internal diameter.
The difference between the two values is fundamental, since this determines
the head of liquid providing the pressure driving the boiling flow through the
plate-fin exchanger inside the kettle.

See also:
Plate-fin Kettles
 PlateFin: Number of Nozzles on Kettle
You can specify the number of nozzles one a kettle containing a plate-fin
exchanger. This value does not affect the calculated performance of the
exchanger, but will affect the estimated entrainment of droplets in the vapor
leaving the kettle.
See also:
Plate-fin Kettles
 PlateFin: Layer Types
The information that appears on the Layer Types screen is specific to the
Layer Type (Layer A, Layer B, etc.) specified in the Layer Types field at the
top of the screen.
Each Layer Type has the following inputs:
· Number of Layers (as also shown on the Layer Pattern screen)
· Number of Streams in this layer
· Fraction Double Banked (as also shown on the Layer Pattern screen)
· Layer Group (Crossflow)

and a table showing the sequence of the following inputs in the layer
· Layer element type
· Element identifier
· Element axial length
· Element distance from end A

In this table, specify the sequence of components in the layer, beginning at

the top of the exchanger (defined as end A) or in general, the hot end of the
exchanger.
When the input for one layer type is complete, select the next Layer Type in
the drop-down field at the top of the screen and provide information for the
next layer type.
Since Layer type input is for one layer type at a time, a schematic diagram is
provided, showing the lengths of all items in all layer types.
 PlateFin: Number of Streams in this Layer
This item is the number of streams occurring along the length of the selected
layer type. It enables the program to display a default set of layer elements in
the selected layer type.
 PlateFin: Layer Element Type
The sequence of layer elements for each layer type is fundamental to defining
the structure of a plate-fin exchanger. You will initially see a set of defaults.
You can change any item, and the remaining defaults will change
correspondingly.
After an initial end bar, the basic default sequence for each stream in the
layer type (after an initial end bar) is:
· Distributor (in)
· Main fin
· Distributor (out)
· End bar
If you set the Number of streams in layer to more than one, you will see this
sequence repeated for each stream.
If you edit the first distributor to be of type (out), the second will change to
type (in).
In general, if you modify any item, any defaults below it will change. The
corresponding defaults in the other columns in the table will also adjust
accordingly.
The sequence of layer elements always terminates in the default item
Unspecified which should have zero length if the length of all other elements
in the layer type sum to the exchanger length.
With many exchangers, only the four layer element types above will be
needed. However, many more possibilities are provided. The full list of options
you can select from is as follows:

Set default

Inlet distributor (stream) number distributor number= stream number, normally

Outlet distributor (stream) number distributor number= stream number, normally

Main fin: fin number fin number in fin data input

End bar

Redistributor-outflow Part flow to intermediate header, or partial draw-off

Redistributor-inflow Part flow from intermediate header

Inlet intermediate distributor number All flow from intermediate header

Outlet intermediate distributor number All flow to intermediate header

Hardway fin Serrated or perforated fin transverse to flow

Inactive fin Fin with no flow

X-flow main inlet: stream number From header with main inflow, for crossflow pass

X-flow main outlet: stream number To header with main outflow, for crossflow pass

X-flow finning: fin number Fin carrying crossflow stream

X-flow pass inlet: header number From header between crossflow passes

X-flow pass out: header number To header between crossflow passes

Multipass X-flow fin: fin number C rossflow with multiple passes, internal turnaround

Multipass X-flow: number of passes After preceding item, giving number of passes

Unspecified

See also:
Layer element Types - more information
 PlateFin: Element Identifier
Most element types need an element identifier, which is often mandatory.
The element identifier depends on the element type as follows:
For an inlet or outlet distributor, the element identifier is the distributor
number, which is normally the same as the stream number. The exception is
when a stream has different distributor geometries in different layer types,
for which a distributor number above the highest stream number in the
exchanger must be identified. See Number of Distributor Types
For finning, either a main fin, X-flow fin, multipass X-flow fin, inactive fin or
hardway fin, the identifier is one of the following fin numbers:
· The simple fin number for which you provide geometry data, or
· A fin number from a fin data bank you have provided for use with the
program
For redistributors or intermediate distributors, you need to allocate a
distributor number. By default, this is the same as the stream number;
however, you can select any number, so that a stream can have more than
one redistributor. The intermediate distributor corresponding to a
redistributor should have a matching distributor number, even though it is in
a different layer type.
For X-flow main inlet and outlet, the identifier is both distributor number
and stream number, as these must be identical.
For X-flow pass inlet and outlet, the identifier is the header number. This
should normally be left set to the default allocated by the program. Attention
need only be paid to this identifier when more than one crossflow layer type
is linked to the same intermediate distributor between crossflow passes.
 PlateFin: Element Axial Length and Element
Distance from End A
For every element along the length of a layer type, you should specify either
an axial length or the distance from end A. The distance from end A is the
sum of the element length and the length of all elements proceeding (above)
it. You can specify either input. The other ones will be automatically
calculated and show as a default. You can also specify a mixture of the two
inputs, but this increases the risk of inconsistencies.
If you have specified the exchanger length, then this is used in calculating the
length of the last element in the layer which is always unspecified and should
normally have zero length if other lengths are correct.
For distributors of all types, you can specify the axial length of the distributor
twice: once under layer types, and once under distributors. The two values
are often identical, but this is not mandatory. The distinction can be useful if
you have a diagonal inlet distributor for one stream, and outlet distributor for
another adjacent and occupying an overlapping region of exchanger length.
You should artificially split the overlapping length between the two
distributors in the layer information, but supply the correct axial length for
each in the distributor information.
Since Layer type input is for one layer type at a time, a schematic diagram is
provided, showing the lengths of all items in all layer types.
 PlateFin: Distributors
The Distributors section includes the following screens:
Standard Distributors
Special Distributors

Standard distributors refer to the main inlet and outlet distributors for each
stream.
Special distributors refer to all other distributors, such as redistributors or
intermediate distributors to or from which fluid is transferred by a
redistributor.
 PlateFin: Standard Distributors
The Standard Distributors section includes the following inputs:
Inlet Distributors
Stream Number
Inlet Distributor Type
Inlet Header Location
Dimension a (axial length)
Dimension b
Fin code number for Pad 1
Fin code number for Pad 2
Inlet Nozzle Inside Diameter
Number of Inlet Nozzles/Unit

Outlet Distributors
Outlet Distributor Type
Outlet Header Location
Dimension a (axial length)
Dimension b
Fin code number for Pad 1
Fin code number for Pad 2
Outlet Nozzle Inside Diameter
Number of Outlet Nozzles/Unit

All these input items are optional in Design mode.

See also:
Notes on Distributors and Headers
 PlateFin: Stream Number (Distributors and
Headers)
Distributor and header geometries are identified by a distributor number,
which is referred to in the layer pattern. The stream number for each
distributor number must therefore be identified. It is normally the same as
the stream number. They are set equal by default.
Note: The stream number and distributor number MUST be the same for
distributors with numbers up to the number of streams in the exchanger.
Every stream must have an inlet and outlet distributor identified – though the
Distributor type can be None or Header only.
The distinction between distributor and header number is used to handle
cases where a stream has more than one such geometry. For example, the
stream can flow in two layer types with different heights, so the distributors
use different fins. Additional distributors must have distributor numbers
higher than the highest stream number. To permit this, the Number of
Distributor Types on the Application Options tab must be set to a value
above the number of streams.
 PlateFin: Distributor Type
Enter the distributor type for the inlet or outlet distributor, followed by
information on the header location, fin pads, and size, as shown in the
diagram.
In addition to the options shown in the diagrams, you may select “not set,”
which means that no distributor pressure drop (or heat transfer) calculations
will be performed for that distributor. You do not need to enter any further
information for it.

See also:
Notes on Distributors and Headers
 PlateFin: Header Location
Enter the header location for the inlet or outlet distributor, indicating whether
the header is on the left and or right hand side, or if it is a twin with headers
on both side of the exchanger.
See also:
Notes on Distributors and Headers
 PlateFin: Dimension a and b (axial length)
Dimension a is the length along the exchanger occupied by the distributor.
Dimension b is the other dimension, when needed, according to distributor
type.
Side Entry Exit Distributors

End Entry Exit Distriburots

Redistributor, fin pads, and dimensions

(for either combining or dividing redistributor)
See also:
Notes on Distributors and Headers
 PlateFin: Fin Code Number for Pad 1
Enter a number to identify the fin used in outlet distributor pad 1 (adjacent to
the header). The number may refer directly to the fin number in the Fins
(geometry) or Fin Performance inputs, or to a fin number in a user databank.

See also:
Notes on Distributors and Headers
 PlateFin: Fin Code Number for Pad 2
If an outlet distributor has two fin pads and if they use different finning, you
should enter a number to identify the fin used in distributor pad 2. If omitted,
the default is the same fin as in pad 1. (Pad 1 is adjacent to the header).
Having different finning in the two pads of a distributor is unusual.
The number can refer directly to the fin number in the Fins (geometry) or Fin
Performance inputs, or to a fin number in a user databank.

See also:
Notes on Distributors and Headers
 PlateFin: Nozzle Inside Diameter
Enter the internal diameter of the nozzle (stub) on the inlet or outlet
distributor. If omitted in Simulation mode, the inlet nozzle pressure loss will
not be calculated.

See also:
Notes on Distributors and Headers
 PlateFin: Number of Nozzles/Unit
Enter the number of the nozzles of this type (inlet, outlet etc) per unit. A unit
is a linked set of exchangers welded together, so that they have common
headers, in most cases with a single nozzle on the header, feeding, or
receiving from, all the exchangers in the linked set.

See also:
Notes on Distributors and Headers
 PlateFin: Special Distributors
Special distributors are located at some point along the exchanger between
the main inlet and outlet of an axial flow stream.
The special distributors can be redistributors (combining or dividing) or the
corresponding intermediate distributor. An outlet intermediate distributor
feeds the stream in a layer to a header, and thence to a combining
redistributor in other layers. An inlet intermediate distributor receives fluid
from the header of a dividing redistributor. Geometrically, intermediate
distributors are identical with a main inlet/outlet distributor with side
entry/exit.
When a redistributor is used for partial draw-off, there is (usually) no
corresponding intermediate distributor, but the redistributor nozzle has draw-
off nozzles.
The screen includes the following inputs for both the redistributor and its
associated intermediate distributor:
Stream Number
Redistributor Type
Dimension a (axial length)
Dimension b
Fin code number for Redistributor Pad 1
Fin code number for Redistributor Pad 2
Fin code number for Redistributor Pad 3

Intermediate Distributor Type

Dimension a (axial length)
Dimension b
Fin code number for Pad 1
Fin code number for Pad 2

Intermediate Header Type

Redistributor Header Location
Header Number
Draw-off Point Number
Draw-off Nozzle Inside Diameter (only for partial draw-off)
Number of Draw-off Nozzles/unit (only for partial draw-off)

See Also:
Flow Fraction in Header
 PlateFin: Stream Number
Redistributors and intermediate distributors are identified by a distributor
number, unlike main inlet and outlet distributors, which are identified by a
stream number. This means that a stream can in principle have multiple
redistributions.
The stream number must therefore be identified for each distributor. In
simple cases with a single redistributor, the distributor number defaults to the
stream number, so the distributor number and the stream number in it are
the same.
 PlateFin: Redistributor Type
A redistributor can be either of the standard type (with three fin pads) or a
hardway distributor.
For standard redistributors, the flow through the layer is in pads 1 and 2,
while the flow entering or leaving the layer (via a header) flows through fin
pad 3. The diagram shows the flows in a dividing redistributor. In a combining
redistributor the flow directions are reversed.

The distributor geometry (dimension b of a standard redistributor) affects the

fraction of the flow going to the header and should match the number (and
relative height) of the layers into which flow is delivered. If it does not, there
is a warning, and PlateFin assumes that the relative numbers and heights of
layers determine the fraction transferred from one layer to another. Uniform
mass flux is assumed in all the layers downstream of the redistribution point.
Hardway redistributors impose no constraint on the flow fraction going to the
header. For this reason, they are usually the preferred geometry with partial
draw-off.
 PlateFin: Fin Code Number for Redistributor
Pad 1
Enter a number to identify the fin used in redistributor pad 1. In a normal
(dividing) redistributor, this is the first fin pad which carries that part of the
flow which remains in the same layers.
The number refers to your definition of the fin and will be in the range 1-15
or a fin in a user databank.

See also:
Notes on Distributors and Headers
Notes on Internal Redistribution
 PlateFin: Fin Code Number for Redistributor
Pad 2
Enter a number to identify the fin used in redistributor pad 2. In a normal
(dividing) redistributor, this is the second fin pad which carries that part of
the flow which remains in the same layers. If omitted the same fin as pad 1 is
assumed, which is normally the case.
The number refers to your definition of the fin and will be one of the fins for
which you have provided data in the input file, or a fin in a user databank.

See also:
Notes on Distributors and Headers
Notes on Internal Redistribution
 PlateFin: Fin Code Number for Redistributor
Pad 3
Enter a number to identify the fin used in redistributor pad 3. In a normal
(dividing) redistributor, this is the fin pad which carries that part of the flow
which transfers to the extra layers. If omitted the same fin as pad 1 is
assumed, which is normally the case.
The number refers to your definition of the fin and will be one of the fins for
which you have provided data in the input file, or a fin in a user databank.

See also:
Notes on Distributors and Headers
Notes on Internal Redistribution
 PlateFin: Intermediate Distributor
See Distributor type for main inlet outlet distributors. In intermediate
distributor can have equivalent geometry to a main distributor with the
header on the side of the exchanger.
 PlateFin: Intermediate Header Type
This item lets you define whether the redistributor header is a normal one, in
that its function is simply to transfer flow from one set of layers to another, or
whether it is the location of a partial draw-off nozzle which removes part of
the process stream flow.
When there is partial draw-off, the draw-off point number, as identified in the
process data, must be specified. This is to assist with the possibility of a
stream having more than one partial draw-off points before it leaves the
exchanger.
 PlateFin: Redistributor Header Location
Specify whether the header for the redistributor is on the left or right hand
side of the exchanger. The corresponding intermediate distributor uses the
same header.
 PlateFin: Header Number
The header number can be specified for the header associated with a
redistributor or intermediate distributor. It can usually be left set to the
default. It is used to identify the header when there is a redistributor in more
than one layer type, or an intermediate distributor in more than one layer
type, connected to the same header. It is also important when an exchanger
has more than one intermediate header.
 PlateFin: Draw-off Point Number
A partial draw off point number is allocated to each point at which part of the
flow of a stream is removed from an exchanger at an intermediate header.
More than one such point in an exchanger is possible, but unusual. For partial
draw-off, the estimated process conditions at the point must be specified, and
the redistributor(s) delivering the flow to the partial draw-off point must be
identified in a layer type. If the input for partial draw-off point number is
grayed out, it implies some of this information is missing.
See also:
Partial Draw-Off
 PlateFin: Notes on Distributors and Headers
There are seven basic types of distributors. Some are side entry or exit,
others are end entry or exit. For each distributor, it is necessary to identify
the distributor type, and the side of the exchanger on which the associated
header is located (or whether it is a twin headed distributor).
In diagrams of distributors, headers on the left hand side, at the top of the
exchanger are shown. But the equivalent distributors with headers on the
right hand side, and/or at the bottom of the exchanger are also possible. Twin
headed distributors are also used in some cases. The basic distributor form is
then repeated in each half the exchanger width.
It is also necessary to specify either one or two lengths associated with the
distributor, dimensions a and b. In all cases dimension a represents the axial
length of the distributor, and dimension b is its other key dimension.
The distributor fins must also be identified. If there are two fin pads used in
the distributor, each can be identified separately. Fin pad 1 is always the pad
next to the header.
Distributors are identified by a code. Types 1-7 are the basic, left hand side
versions (strictly types 1 and 3 are centrally symmetric). Right handed form is
identified by a negative number, -2, -4 etc. and a twin (double headed) form
is identified by adding 10 to the basic number. Type 12 is twin end entry, type
14 twin diagonal side entry, and so on.
Hardway distributors have either perforated or serrated finning laid
transverse to the main exchanger axis so that flow along the exchanger is via
the perforations, but flow to or from the header is along the fin. The minimum
perforation fraction for hardway finning is normally 25 percent.
Distributors are assumed to contribute to both the heat transfer and the
pressure loss in an exchanger. There is however an option not to calculate the
heat transfer. Pressure drop calculations are rigorous, allowing explicitly for
the different mass flux and flow length in the different fin types. Heat transfer
calculations use approximations to allow for averaging the mass flux, and
fraction of the exchanger width with distributor flow, at any point within the
distributor. For side entry distributors on axial flow streams, the stream is
assumed to enter the exchanger half-way along the distributor entry region.
For Simulation modes, distributor input is optional. If you want to omit
distributor data, specify None for distributor type. Distributor pressure losses
are only calculated when distributor information is provided. Total pressure
loss will be affected accordingly.
You can also specify a distributor as Header only meaning that no distributor
geometry is provided, and no heat transfer or pressure drop calculations are
performed. Header only is the mandatory distributor type for crossflow
streams.
In Design mode, distributors are always designed whether or not input is
provided. If you can specify part of the information for a distributor, the
remainder will be set by the Design process.
Headers can span multiple exchanger blocks welded into a common Unit. You
can specify the number of nozzles per header.
 PlateFin: Notes on Internal Redistribution
When a stream is only present for part of the length of a set of layers, a
second stream is sometimes diverted from another set of layers to occupy the
otherwise empty region of the first set. This second stream must then have a
redistributor in the first set of layers (layer type) to divert part of its flow to a
header on the outside of the core, and the second set must have an inlet
intermediate distributor to take this flow back into the otherwise empty
layers. The stream is initially in a single set of layers and ends up in two sets.
This is a dividing redistribution. The alternative, combining redistribution, has
the stream initially in two sets of layers. The flow in one layer terminates at
an outlet intermediate distributor, and flows into a header, from which it
enters the other set of layers via a combining redistributor.

Redistributors are also used, without a re-inlet distributor, when part of a

stream is drawn off at some point along the exchanger. This is partial draw-
off. The draw-off point number must be specified. You must also specify
estimated process conditions at the partial draw-off point, under the Process
Data input. See Partial Draw-Off.
A redistributor and its corresponding intermediate distributor will be in
different layer types. You should check that you have specified them to occur
at the same location along the exchanger so they can share a common
header. You can check using the exchanger diagram where you will see two
headers drawn, one for the redistributor and one for the intermediate
distributor
Pressure losses in a redistributor and intermediate distributor are calculated
in detail. Heat transfer is also allowed for, making some approximations,
unless you specify that distributor heat transfer should be ignored.
Redistributors can be modeled in simulation calculations for axial flow
exchanger. Crossflow exchangers do not normally have redistributors.
In Design mode, you can design exchangers with redistributors, but you
cannot specify their geometry or location. You can control their use by
specifying same layer as stream facility, under Design options.
 PlateFin: Flow Fraction in Header
The flow fraction going into to a header from a redistributor is not an input
item in PlateFin, but is determined by the program on the basis of equal
(superficial) mass flux in all the layers carrying the stream downstream of a
redistribution point. The superficial mass flux takes into account the number
and height of layers of each type.
With a standard redistributor, the geometry needs to be matched to the flow
fraction. If it is not matched, a warning is produced, but it is otherwise
ignored.

See also:
Notes on Distributors and Headers
 PlateFin: Exchanger Diagram
The Exchanger Diagram in the program input is drawn automatically after you
have provided adequate information on the exchanger width and number of
layers, on the structure of each layer type, and on the distributors.
Right-clicking the diagram lets you select any layer type and view its
structure.
The input exchanger diagram is not available in Design mode.
In all calculation modes, an equivalent diagram of the exchanger forms part
of the program output.
 PlateFin: Fins
The Fins section includes a single screen which lets you select, specify, and
review the geometry for each fin in turn:
Fin Geometry
Fins are identified by numbers, which are referred to elsewhere in the input,
for example under Layer types and Distributors.
If these references are to numbers in the main series 1-16, then you must
specify the geometry for the fin (or in Design mode, any part of the geometry
you wish).
If the references are to fin numbers in fin databanks which you have provided
(with databank numbers in the rage 101-9999), then geometry and
performance data for that fin will be read from the databank and displayed in
the input.
 PlateFin: Fin Geometry
The Fin Geometry screen includes the following inputs:
Fin Code/Bank Number
Fin Used in Exchanger
Fin Type
Fin Height
Fin Thickness
Fin Frequency
Fin Porosity (fraction)
Fin Serration Length

For any fin from a fin databank, geometry (and performance data) for that fin
will be read from the databank and displayed in the input.
 PlateFin: Fin Code/Bank Number
If the fin is from a databank, this will show the databank number. If it is not,
this item is simply the number of the fin.
 PlateFin: Fin used in Exchanger
This item records whether this fin has been referred to elsewhere in the
input, for example as a main fin in some layer type, or as a distributor fin.
If the default for this item is set to “No” for some fin, you should check
whether this indicates an error, and you should have referred to this fin
elsewhere in the input.
The default will never be “no” if the fin is from a databank, as only databank
fins that are referred to are incorporated into the set of fins used. Databank
fins are given fin numbers following the highest fin number referred to by a
standard number in the range 1-16.
 PlateFin: Fin Type
You should select the type of fin, plain, perforated, serrated, or wavy, or you
can indicate that there are no fins.

No finsis not applicable to plate-fin exchangers, but may be useful if the

program is being used to model some other form of layered exchanger.
 PlateFin: Fin Height
The fin height is the distance between the separating plates (parting sheets).
This applies to all fin types. All the fins (main fin and distributor) for a stream
must have the same height. A warning is issued if this is not so.
Fin height must be supplied in simulation modes but is optional in design
mode.
 PlateFin: Fin Thickness
Enter the fin thickness.
This item may be zero if no fins are present.
Fin thickness must be supplied in simulation modes but is optional in design
mode.
 PlateFin: Fin Frequency
Enter the number of fins per meter (SI or Metric units) or the number of fins
per inch, fpi (US units).
This item may be zero if no fins are present.
Common fin frequencies are 16, 18, or 21 fpi for main fins, and 6 or 8 fpi for
distributor fins.
Fin frequency must be supplied in simulation modes but is optional in design
mode.
 PlateFin: Fin Porosity (fraction)
For perforated fins, enter the fin porosity as a fraction - the fraction as metals
lost as holes.
For fins other than perforated, this item should be zero.
Fin porosity must be supplied in simulation modes.
In design mode, it is optional - five percent (0.05) will normally be selected.
 PlateFin: Fin Serration Length
For serrated fins, enter the fin serration length.
The default is 3 mm (approximately 1/8 inch), which is typical of values used
by most manufacturers. Some manufacturers also make fins with a longer
serration length. These have somewhat reduced heat transfer and pressure
drop and are an alternative to wavy fins.
This input item is only needed for such long-serration length serrated fins.
 PlateFin: Fin Performance
The Fin Performance screen is primarily a table giving a set of values for
three parameters:
Reynolds Number (Re)
Friction Factor (f)
Colburn j Factor (Cj)

It also displays the following inputs for cross-referencing:

Fin Code/Bank Number
Fin used in Exchanger
Fin Type
Prandtl Number Correction to Cj
Re-f-Cj for Hardway

For any fin from a fin databank, performance data for that fin will be read
from the databank and displayed in the input.
For other fins, once fin geometry data have been supplied, default values of
fin performance data (Re-f-Cj) will be supplied based on HTFS correlations.
You can override these performance data with your own input values.
 PlateFin: Reynolds Number (Re), Friction Factor
(f), Colburn j Factor (Cj)
Fin performance data consists of a table of Reynolds numbers, at each of
which is provided a Friction factor (f) (for determining frictional pressure
losses) and a Colburn-J (Cj) factor for determining heat transfer coefficients.
If you input fin geometry data, the table is populated with a set of default
Reynolds numbers, covering a wide range, and the corresponding friction and
Cj factors, derived from HTFS correlations for that geometry. If the fin is from
a databank, then values read from the databank are shown.
You may overwrite the default values in the table and supply your own data,
if you wish.
When the program is run, the values in the table are interpolated (on a log-
log basis), and if necessary extrapolated, to give values at any required
Reynolds number needed for pressure drop and heat transfer calculations.
For all fin types, the flow areas and hydraulic diameters associated with Re-f-
Cj data are based on the geometry of the equivalent plain fin.
 PlateFin: Prandtl Number Correction to Cj
The Colburn j-factor, Cj, expressed only as a function of Reynolds number,
strictly applies only for turbulent flow at moderate or high Reynolds numbers.
For laminar flow, Cj also depends on Prandtl number. A Prandtl number (Pr)
correction needs to be applied, assuming the Cj value supplied relates to Pr
values close to unity, as is the case if the Cj data have been measured for
gaseous flows. The correction is most significant for plain and perforated fins
and is relatively small for serrated fins.
The input here should normally be left set to the default value of 1, indicating
that the Pr correction will be applied to the default or input or databank Cj
values. A value of zero indicates that no correction will be applied. Values
between 0 and 1 can be input to limit the extent of the correction.
You should set a value of zero if the fluid flowing in the fin has a high Prantdl
number (for example an oil), and the Cj data you supply have been measured
for that oil.
 PlateFin: Re-f-Cj for Hardway
Hardway finning is perforated or serrated fin set transversely to the flow
direction to provide a region of high flow resistance. This can assist in
achieving uniform flow distribution across the exchanger.
Set this item to Yes if the fin concerned is used as hardway, and the
performance data you have supplied for it (Re-f-Cj) relate to the hardway
orientation.
If this flag is not set, HTFS approximations for hardway will be used, assuming
the performance data supplied relate to conventional flow through the fins.
If the flag is set, but the fin is not used for hardway, standard HTFS
correlations for axial flow in this fin will be used.
For hardway redistributors, there is both axial and transverse flow, so an
appropriate combination of methods is used.
 PlateFin: Thermosiphons
The Thermosiphons section includes the following screens:
Thermosiphon Definition
A thermosiphon stream is a boiling stream where the two-phase outflow is fed
back to the vessel - usually the sump of distillation column – containing the
pool of liquid feeding the stream to the exchanger. The thermosiphon can be
an internal reboiler (the exchanger is immersed in the pool of liquid) or an
external reboiler (there is pipework carrying thermosiphon stream from and
back to the column).
A key feature of a thermosiphon stream is that the stream flowrate is
determined by a pressure balance involving frictional losses in the exchanger
(and pipework if any) and the gravitational head of liquid between the surface
of the liquid in the column, and the point where the thermosiphon stream
enters the exchanger. The program can be used to determine either the
flowrate of the thermosiphon stream for a given gravity head (submergence)
driving the flow, or to find the submergence required to generate a specified
flowrate.
To access thermosiphon input, you must specify the number of thermosiphon
streams (usually just one) on the application options form, and under Process
options, you should select thermosiphon under stream type, given the
choice hot/cold/thermosiphon.
 PlateFin: Thermosiphon Definition
The Thermosiphon Definition screen includes the following inputs:
Stream Number (for thermosiphon)
Thermosiphon Type
Thermosiphon Calculation
Height of Column Liquid Level
Height of Exchanger Inlet
Height of Return Line to Column
Pressure in Column
Head Loss % in Inlet Pipe
Head Loss % in Outlet Pipe

When there is pipework connecting the exchanger and the column, then
pressure losses in this pipework can be determined either by specifying the
detail of the pipework components or by simply specifying the percentage of
head loss in the inlet and outlet lines. Select the appropriate Thermosiphon
type to specify which option you want.
To access thermosiphon input, you must specify the number of thermosiphon
streams (usually just one) on the application options form.
 PlateFin: Stream number (for thermosiphon)
Specify the stream number of the thermosiphon stream. This should be set
automatically for the stream which you have identified as Thermosiphion
under Process Options | Stream type.
In the initial release of PlateFin, only one stream can be a thermosiphon.
Multiple thermosiphons will be permitted in future releases.
 PlateFin: Thermosiphon Type
Specify whether the thermosiphon is internal (immersed in the pool of liquid
in the sump of a distillation column) or external (connected by pipework to
the sump or other vessel feeding the liquid to the exchanger). For external
thermosiphons, specify whether you are explicitly specifying the pipework, or
simply defining a pipework pressure loss as a fraction of the head of liquid
driving the flow.
 PlateFin: Thermosiphon Calculation
Specify whether the program should:
· Calculate the thermosiphon stream flowrate, for a specified submergence
· Calculate the submergence required to drive a given thermosiphon flow
· Calculate the change in inlet pipe pressure loss to give a pressure
balance with the specified flow and submergence
In each case, an initial value of the quantity being calculated (flowrate or
height of liquid level) should be supplied.
 PlateFin: Height of Column Liquid Level
Enter the height of the liquid surface in the column. This may be relative to
any datum level, as long as the same datum is used for all heights.
When a thermosiphon submergence is being calculated, the value supplied is
taken as an initial estimate, which will be modified to achieve the required
flowrate.
 PlateFin: Height of Exchanger Inlet
Enter the height of the liquid inlet in the column. This may be relative to any
datum level, as long as the same datum is used for all heights.
The liquid inlet is defined using the outer surface of the rectangular block
which forms the exchanger core. Headers and stubs/nozzles are ignored. If
the liquid enters on the side of a vertical exchanger, use the height of the
point at the center of the entry slots to the distributor.
 PlateFin: Height of Return Line to Column
Enter the height of the return line the column. Use the center line height of
return pipework. Heights may be relative to any datum level, as long as the
same datum is used for all heights.
This item is not needed for internal reboilers where the return height is the
point of exit from the exchanger, which can be deduced from known
exchanger dimensions.
 PlateFin: Pressure in Column
Enter the pressure at the surface of the liquid in the sump/vessel providing
the thermosiphon feed.
The pressure in the column, plus the gravitational increase to the exchanger
inlet, less any frictional losses in the inlet pipework, gives the exchanger inlet
pressure. If this pressure at the inlet to the exchanger is also entered, it is
taken as an initial approximation. The inlet pressure is recalculated when
frictional losses change, as the flowrate or submergence is modified.
This pressure should have already been specified under the Process data, so a
default will appear. The pressure defined here and in the Process data must
be the same. If different values are entered, an error will result.

See also:
Pressure at Liquid Surface (ThSiph)
 PlateFin: Head Loss % in Inlet Pipe
For an external thermosiphon reboiler, frictional losses in the inlet and outlet
pipework can be calculated either by specifying the geometric detail of the
pipework or by specifying the friction losses as a percentage of the driving
head of liquid. Use the Thermosiphon type input to select which method.
Specification as a percentage can be useful for initial estimates when the
details of the pipework are unknown.
Specify here the friction losses in the Inlet pipework as a percentage of the
head of liquid driving the flow. The driving head of liquid is defined using the
density of the inflowing liquid and the height difference between the liquid
surface in the column sump, and the inlet point to the exchanger.
A moderately high value of loss in the inlet pipe can help improve the
operational stability of a thermosiphon.
 PlateFin: Head Loss % in Outlet Pipe
For an external thermosiphon reboiler, losses in frictional losses in the inlet
and outlet pipework can be calculated either by specifying the geometric
detail of the pipework or by specifying the friction losses as a percentage of
the driving head of liquid. Use the Thermosiphon type input to select which
method. Specification as a percentage can be useful for initial estimates when
the details of the pipework are unknown.
Specify here the friction losses in the Outlet pipework as a percentage of the
head of liquid driving the flow. The driving head of liquid is defined using the
density of the inflowing liquid, and the height difference between the liquid
surface in the column sump and the inlet point to the exchanger.
The outlet pipework carries two phase flow and include at least one bend, so
some frictional loss is inevitable. A high loss in the outlet pipe may, however,
reduce the operational stability of a thermosiphon as well as increasing the
boiling pressure and temperature in the thermosiphon.
 PlateFin: Pipework
The Pipework section includes the following screens:
Pipework
Pipework can be specified as a series of pipework elements. When pipework
pressure changes are small relative to the absolute pressure, modeling the
exact sequence of pipework elements can be of minor importance. For
example, a sequence of 5 bends contained within a 20m length of pipe can be
modeled as two elements, one of five bends and one of a single length of pipe,
rather than a sequence of nine or ten elements, pipe, bend, pipe, bend etc.
The pipework input at present relates only to the inlet and outlet pipework of
external thermosiphon reboilers, but it is designed so that it can be
generalized in future releases.
Pipework information is needed when the Specify pipework option is chosen
for external thermosiphon reboilers. If an approximation to pipework losses is
adequate, you can simply select the option to specify the losses as
percentages of the driving head.
In the first release of the program, only one set of pipework can be defined
and that only for thermosiphon reboilers.
 PlateFin: Pipework
The Pipework screen includes the following inputs:
Pipework for (number)
Pipework for (type)

Inlet Pipe Element Type

Internal Diameter
Length (pipe) or Radius (arc bend)
Velocity Heads (general element)
Elements in Parallel
Elements in Series

Outlet Pipe Element Type

Internal Diameter
Length (pipe) or Radius (arc bend)
Velocity Heads (general element)
Elements in Parallel
Elements in Series
Pipework can be specified as a series of pipework elements. When pipework
pressure changes are small relative to the absolute pressure, modeling the
exact sequence of pipework elements can be of minor importance. For
example a sequence of 5 bends, contained within a 20m length of pipe can be
modeled as two elements, one of five bends and one of a single length of pipe,
rather than a sequence of nine or ten elements, pipe, bend, pipe, bend, etc.
 PlateFin: Pipework for (number)
This input is the stream number to which the pipework relates. In the first
release of PlateFin, this must be the thermosiphon stream.
 PlateFin: Pipework for (type)
You can specify whether the pipework is the main inlet or outlet pipework for
a stream (as with a thermosiphon reboiler) or if it is some other form of
pipework, for example associated with draw-off.
At present only the (main) stream pipework option is available and that only
for thermosiphon streams. This input is not available in the first release of
PlateFin.
 PlateFin: Element Type
Select the type of pipework element in the inlet or outlet pipe.
For any element that is not explicitly available from the drop-down list (for
example, valves or flow measurement devices), you can specify a “general
element” and then give the number of velocity heads lost in that element.
The sequence of elements should match the flow sequence; however this can
be of secondary importance when pressure changes are a small compared
with the absolute pressure, or for liquids, where properties do not change
significantly with pressure.
The sequence of elements is also important when there is a change in
diameter or a change in the number of elements in series. An expansion or
contraction unit is automatically introduced when there is a change in
diameter, and a manifold is introduced when there is a change in the number
of elements in parallel.
 PlateFin: Internal Diameter
Enter the internal diameter of the pipework element. By default, this is the
same as the diameter of the preceding element.
When there are changes in diameter, additional losses due to an expansion or
contraction unit are introduced automatically.
 PlateFin: Length (pipe) or Radius (arc bend)
For straight pipe, horizontal or vertical, enter the length of pipe. For arc
bends, enter the center-line radius. This element is not needed for other
elements.
It is possible to represent an entire length of pipework as a single element
with an appropriate effective length, but it is preferable to explicitly specify
bends and other flow resistance elements.
 PlateFin: Velocity Heads (general element)
For any element that is not explicitly available from the drop-down list (for
example, valves or flow measurement devices), you can specify a general
element.
For any general element, you should specify the number of velocity heads
lost.
 PlateFin: Elements in Parallel
Normally a pipe consists of a set of single elements in parallel.
You should specify multiple elements in parallel if there are multiple
exchangers in parallel, each fed by a single pipe.
If two successive elements in the pipework have a different number of
elements in parallel, it is assumed there is a manifold, and pressure losses
associated with this are calculated.
 PlateFin: Elements in Series
You can specify multiple elements in series. This can be particularly useful for
multiple bends, as it avoids the need to specify separately each bend and each
element of pipe between bends.
For multiple pipework elements with no change of diameter, you should
simply add up the total length rather than specify multiple elements in series.
 PlateFin: Program Options
The Program Options section includes the following sections:
Design Options
Thermal Analysis
Calculation Options
 PlateFin: Design Options
The Design Options section includes the following screens:
Design Calculation
Design Limits
Stream Design
 PlateFin: Design Calculation
The Design Calculation screen includes the following inputs:
Geometry Data Used
Flow Scaling Factor
Area Scaling Factor
Gravity in Design Pressure Drops
Double Banking Priority
Target Depth/Width Ratio
Design Trace Output
Resistance Method for Length
Longitudinal Conduction Method
Number of Heat Load Intervals

The defaults shown by the program should be appropriate in most cases.

Remember that the Design produced is a “first shot” design. A full design can
normally only be produced by a manufacturer, who will have proprietary
performance data for specific fins, and will undertake full mechanical
calculations and layer pattern definition which are beyond the scope of a first
shot Design.
 PlateFin: Geometry Data used
A Design calculation requires no geometric data input, but has the ability to
use any geometry data provided, and as far as possible incorporate this into
the design.
This input item gives further control of which geometry is selected, so that
you can specify that even if geometry data are present, they should be
ignored in the Design process. This can eliminate the need to delete input
data.
At one extreme, even if you have a fully specified exchanger, you can switch
to a Design calculation and specify that all the geometry input be ignored in
order to find out whether an a significantly different exchanger would be
appropriate for the duty being modeled.
 PlateFin: Flow Scaling Factor
Normally, an exchanger will be designed with the flow specified in the process
input. You can, however, specify a flow multiplication factor to be used in the
Design. This multiplying factor is applied to the flow of all the streams.
 PlateFin: Area Scaling Factor
The area scaling factor can be used to give a Design margin. A factor of 1.1
gives a 10% margin. Since this margin is at the core of the Design logic, it
ensures that the will be used self-consistently, in its effect on heat transfer
and pressure drop.
 PlateFin: Gravity in Design Pressure Drops
Maximum pressure drop is a fundamental Design constraint, and normally this
would refer to frictional pressure loss. You can, however, chose that
gravitational pressure changes also be included. This option cannot be used
for downflow streams where the combination of gravitational and frictional
changes might lead to a pressure increase rather than decrease.
 PlateFin: Double Banking Priority
Double banking is needed when the number of hot and cold stream layers
differ by more than one. Suppose there are more hot stream layers, then
some hot stream layers must be adjacent to another hot stream layer; in
other words, they are double banked.
If there are multiple hot streams, then it must be decided which of these
layers are double banked. This input item lets you define a priority.
The effect of double banking is equivalent to reducing the fin efficiency of
streams in the double banked layers.
If there is only one hot stream or if all the hot stream layers are double
banked, then this flag will have no effect. In other cases, the effect of this
selection will often be relatively small, particularly if nearly all the hot layers
are double banked or if only a small proportion are double banked.
If there are more cold streams than hot streams, equivalent considerations
apply.
 PlateFin: Target Depth/Width Ratio
This input lets you specify a target value for the ratio of exchanger depth
(sum of layer heights) to exchanger width (layer width). Normally this will be
near, or just above, unity. The balance of manufacturing cost is to have
fewer, wider layers, to achieve a required total flow cross section for each
stream. However having more wider layers may increase the flow cross
section for some streams unnecessarily, since there must be an integer
number of layers for each stream.
The final design selected should have a depth/width ratio close to that
selected, but it will in general be different, particularly if the number of layers
in the exchanger, or of some critical streams within the exchanger, is
relatively small.
 PlateFin: Design Trace Output
The program can produce an output describing how the various decisions
relating to design configuration are made, and how the iteration to find an
appropriate size progresses.
This option is not available with the first release of PlateFin.
 PlateFin: Resistance Method for Length
This parameter influences how a length is calculated for each step along the
heat load curve during a Design sizing calculation. It is relevant when there
are multiple hot streams or multiple cold streams in the step, and it
determines whether the length is selected based on the average thermal
resistance of the streams of each set (hot or cold) of streams or on the
highest thermal resistance. Using the highest thermal resistance will produce
a larger exchanger.
Selecting the highest resistance should ensure that every stream meets its
specified heat load, whereas the average resistance might mean that while on
average the required hot and cold stream loads are met, individual streams
may be marginally under or marginally over the requirement.
 PlateFin: Longitudinal Conduction Method
You can select options for handling longitudinal conduction during Design
calculations.
This option is not available with the first release of PlateFin.
 PlateFin: Number of Heat Load Intervals
The Design calculation is based on composite hot and cold heat load curves,
broken down into a number of calculation steps. Initially, a set of relatively
large steps(intervals) is created, using the point where each stream enters
and leaves and any bubble or dew point within the range. These are the
points where the composite hot and cold curves have slope discontinuities.
These large steps are then broken down into multiple smaller steps, so that a
piecewise-linear approximation to the hot and cold composite curves can be
used.
You can use this input item to modify the total number of steps (intervals)
used in the calculation. The number you used is a target, and the actual
number selected may differ from it because of other constraints on the
selection process. The maximum number of steps used is 200, but smaller
values are often adequate, particularly since the Design is a “first shot”
design.
 PlateFin: Design Limits
The Design Limits screen includes the following inputs:
Maximum Length
Maximum Width
Maximum Depth (stack height)
These constrain the size of exchanger (core) selected in the Design process.
The maximum size of a brazed aluminum unit is normally constrained by the
size and load bearing capacity of the vacuum furnace used for brazing. The
uniformity and controllability of metal temperatures during the brazing
process can also limit exchanger size.
In general, exchangers containing high pressure streams need to be smaller
than low or medium pressure exchangers. No default values are shown in the
input, but if left blank, the program will calculate maximum size dimensions
internally. These calculated values are generally conservative, and some
manufacturers will be able to build larger exchangers.
 PlateFin: Maximum Length
You may explicitly specify the maximum length of an exchanger instead of
using the internally calculated value.
The Design process will generally try to add area by increasing width and
depth rather than by increasing length. If increasing the length is
unavoidable, then multiple exchanges in series may be offered as Design
option. For simplicity, these exchangers are all assumed to have the same
cross section. This probably means that the series exchangers are not
individually optimized.
For more information on maximum dimensions see Design Limits.
 PlateFin: Maximum Width
You may explicitly specify the maximum width of an exchanger instead of
using the internally calculated value.
The Design process will generally try to add area by increasing width and
depth rather than by increasing length. When the maximum width is reached,
however, it is never exceeded. Further area is added by increasing the
number of layers of each stream.
For more information on maximum dimensions see Design Limits.
 PlateFin: Maximum Depth (stack height)
You may explicitly specify the maximum depth of an exchanger instead of
using the internally calculated value. The depth, or stack height, is the sum of
the heights of all the layers in a core.
The Design process will generally try to add area by increasing width and
depth rather than by increasing length. When the maximum depth is reached,
a further exchanger in parallel will be selected if possible. When the
maximum number of exchangers in parallel is reached along with the
maximum width but more flow cross section is needed, then the maximum
depth limit, either specified or calculated internally, will be breached, and a
corresponding warning message issued.
For more information on maximum dimensions see Design Limits.
 PlateFin: Stream Design
The Stream Design screen includes the following inputs:
Number of Layers
Permit Redistribution
Stream following in same layer
Maximum % of allowed Pressure Drop in Nozzle
Main Fin
Second and Subsequent Main Fins
Temperature for Change to nth Main Fin
Hardway Fin
Length of Hardway Fin

The Design process does not require any geometric input but can make use of
any such input you provide.
 PlateFin: Number of Layers (Design)
You may specify the number of layers to be used for any stream in the Design
process. This value will override any calculated value. The exchanger width
and the number of layers of other streams will be adjusted to be consistent
with any number of layers you specify.
A consequence of explicitly specifying the number of layers may be that it is
not possible for the design to meet the maximum pressure drop constraint on
the stream.
 PlateFin: Permit Redistribution
If there is an appropriate location for a stream to be redistributed into, then
the Design process will automatically do so, but you can specify that a stream
should not be redistributed.
 PlateFin: Stream Following in Same Layer
If there are two hot (or cold) streams with non-overlapping temperature
ranges, the Design process will put them in the same layer. If there is a
choice of more than one pair of such streams that could go in the same layer,
the Design logic will select an appropriate pair. If you think this choice might
be inappropriate, you can set this input item to change the choice. For one
stream, specify the number of the other stream that goes in the same layer.
 PlateFin: Maximum % of allowed Pressure Drop
in Nozzle
You can specify the maximum percentage of the total permitted pressure drop
to be used in each nozzle. This input item gives you additional control in
determining nozzle sizes during the Design process.
 PlateFin: Main Fin
The Design process can select an appropriate main fin for each stream. If
however you wish to override this process, you can do so by specifying an
input here. You can either specify a simple fin number, for which you provide
the corresponding geometric data directly, or a fin number in a user data
bank.
To access the option of specifying main fins and other stream geometry data
on the same form, the program must be in Design mode, and the Geometry
data used field on the Design Options screen must be set to either Use all
geometry input or Basic geometry only.
There is a further option, whereby you do not specify the fin exactly but
indicate the type of fin to be used. You can specify -1,-2,-3, or -4, for plain,
perforated, serrated, or wavy, respectively. The program will use this type but
select other geometric details as normal. This option is only available when
there is only one main fin for the stream.
 PlateFin: Second and Subsequent Main Fins
You can specify more than one main fin be used for a stream in the Design
process. If you do so, then you should specify the fins in flow order from end
A to end B. You must also identify the stream temperature at which each
stream transition should take place.
Fins can be identified either by a simple fin number or by a fin number from a
databank.
 PlateFin: Temperature for Change to nth Main
Fin
You can specify more than one main fin be used for a stream in the Design
process. If you do so, then you must specify the fins and the stream
temperatures at which the transition takes place, both in order from end A to
end B.
Since the Design process assumes end A of the exchanger is hot, the
transition temperatures you supply will be in decreasing order for both hot
and cold streams. If a stream is a pure substance that is boiling or condensing
at constant temperature, take care when specifying transitions very close to
the dew or bubble point, as these points will change with pressure.
The Design process will determine the location of each of the fin transitions as
part of the exchanger sizing calculation.
 PlateFin: Hardway Fin
You can specify a short region of Hardway fin at the stream inlet in Design
mode. Hardway is serrated or perforated finning laid transversely to the
normal flow direction. The high pressure drop it generates improves the flow
distribution across the layer width.
You need to specify both the fin number and the length of the hardway fin.
The fin can also be used elsewhere for normal (axial) flow.
During Design, the program initially calculates heat transfer and pressure
drop, ignoring the hardway fin. It calculates the hardway pressure gradient at
the stream inlet, and then corrects both the pressure gradient at any
calculation points within the hardway length and the pressure changes at all
points up to the stream outlet.
You can specify performance data appropriate to the hardway orientation for
the fin that you identified as hardway in Design mode. When a fin is used as
hardway, the hydraulic diameter and flow area per unit width are reported in
the Fin Geometry output for both the normal and hardway flow directions.
 PlateFin: Length of Hardway Fin
When you specify that a hardway fin is used in Design mode, you must also
specify the axial length along the exchanger occupied by this fin.
Hardway lengths are normally relatively short, and in Design calculation,
there may be a very small number of calculation steps in the hardway region,
or even none. When integrations of pressure gradient are made to determine
pressure changes, the transition from hardway to normal flow within one
calculation step is explicitly allowed for.
In Design mode, the heat transfer within the length of the hardway fin is
assumed to be the same as in the adjacent normal fin. If you update the
results of a Design calculation with hardway to a Simulation calculation, then
both heat transfer and pressure change within the hardway region use
specific hardway methods.
 PlateFin: Thermal Analysis
The Thermal Analysis section includes the following screens:
Exchanger
Heat Transfer/Pressure Drop
 PlateFin: Exchanger
The Thermal Analysis screen includes the following inputs:
Heat Leak into Exchanger(s)
Heat Leak uniformity
Fin Thermal Conductivity (end A)
Fin Thermal Conductivity (end B)
Maximum Entrainment Fraction
 PlateFin: Heat Leak into Exchanger(s)
You can specify a heat leak into the exchanger. This leak can vary along the
length of the exchanger (see heat leak uniformity) but is assumed uniform
around the periphery of the exchanger.
In a stream by stream calculation, there is assumed to be a single, uniform
parting sheet temperature at each axial location, and the heat leak feeds
directly into the calculation of this temperature. In layer by layer calculation,
the heat leak feeds into each layer in proportion to the fraction of the
exchanger periphery it occupies. The largest contributions to the heat leak
are thus into the two outer layers. Other layers have a small contribution
from the leak fed into their edges, but since temperature variation across the
parting sheet is not allowed for, the leak affects the whole layer.
A heat leak out of the exchanger can be indicated by specifying a negative
heat leak.
 PlateFin: Heat Leak Uniformity
When you specify a heat leak into an exchanger, you can also specify whether
or not this heat leak is axially uniform along the exchanger.
The heat leak uniformity is the ratio of the heat leak (per unit length) at end
A of the exchanger to the mean value for the exchanger. A linear variation of
heat leak per unit length along the exchanger is assumed.
A value of unity indicates an axially uniform heat leak. When the specified
uniformity is below unity, this mean that the leak at end A is lower than the
mean, and the leak at end B must be correspondingly above the mean.
 PlateFin: Fin Thermal Conductivity (end A)
The thermal conductivity of the finning and other exchanger material is
normally taken from internal tables for the specified exchanger metal. If you
can explicitly specify a conductivity at each end of the exchanger. they will be
based on a linear variation with temperature between the two end values.
The default values of conductivity shown relates to the value from the tables
at the extreme hot stream inlet temperature at end A.
 PlateFin: Fin Thermal Conductivity (end B)
The thermal conductivity of the finning and other exchanger material is
normally taken from internal tables for the specified exchanger metal. If you
explicitly specify a conductivity at each end of the exchanger, the
conductivities will be based on a linear variation with temperature between
the two end values.
If you specify a conductivity at end A, then the conductivity at end B defaults
to the same value, and a uniform conductivity value will be assumed. If you
leave default values unchanged, you will see the value from the tables at the
extreme cold stream inlet temperature at end B.
 PlateFin: Maximum Entrainment Fraction
You can specify a maximum entrainment fraction in the outlet nozzle of a
plate fin kettle reboiler. A warning will be issued if the calculated entrainment
fraction exceeds this value.
Entrainment fractions can be reduced by increasing the number or size of the
nozzles on the kettle.
 PlateFin: Heat Transfer/Pressure Drop
The Heat Transfer/Pressure Drop screen includes the following inputs:
Heat Transfer Area Factor
Fin Performance Correlations

Liquid Heat Transfer Coefficient

Two Phase Heat Transfer Coefficient
Vapor Heat Transfer Coefficient
Multiplier for Liquid Coefficient
Multiplier for Two Phase Coefficient
Multiplier for Vapor Coefficient
Pressure Drop Multiplier
Velocity Heads Lost in Inlet Nozzle
Velocity Heads lost in Outlet Nozzle
Mixing between X-passes
Velocity Head Loss between X-passes
Simple UA: pressure varies with:
Precalculated Coefficients
Preset Delta T for Boiling
HTC (obsolete MUSE option)

It is normally appropriate to leave all the items on this tab set to default
values.

See also:
Precalculated Coefficients
 PlateFin: Heat Transfer Area Factor
You can specify a factor to be used to multiply the heat transfer area when
evaluating how much heat is transferred in each calculation step.
Normally, this factor should be left set to unity, but it is sometimes useful to
specify a lower value when a calculation would otherwise fail to converge.
This could apply when modeling an exchanger in turndown conditions, or
which is otherwise much larger than required for a specific duty. When a
converged solution is found with an area factor below unity, this can be
regarded as specifying a lower limit on the heat load likely to be achieved by
each stream.
 PlateFin: Fin Performance Correlations
This facility should not normally be needed. It lets the program revert to
using the first set of HTFS fin performance correlations, used in earlier
version of the first HTFS program for plate-fin exchangers, MUSE.
The current set of HTFS performance correlations, used in PlateFin, are
identical with those used in recent versions of MUSE.
 PlateFin: Liquid Heat Transfer Coefficient
You can specify a liquid phase heat transfer coefficient to override the value
calculated in the program. This coefficient is based on local area, on the fin or
parting sheet, within the plate-fin channel.
 PlateFin: Two Phase Heat Transfer Coefficient
You can specify a two-phase (boiling or condensing) heat transfer coefficient
to override the value calculated in the program. This coefficient is based on
local area, on the fin or parting sheet, within the plate-fin channel.
 PlateFin: Vapor Heat Transfer Coefficient
You can specify a vapor phase heat transfer coefficient to override the value
calculated in the program. This coefficient is based on local area, on the fin or
parting sheet, within the plate-fin channel.
 PlateFin: Multiplier for Liquid Coefficient
You can specify a multiplier to be applied to the local liquid phase heat
transfer coefficient calculated in the program.
 PlateFin: Multiplier for Two Phase Coefficient
You can specify a multiplier to be applied to the local boiling or condensing
heat transfer coefficient calculated in the program.
 PlateFin: Multiplier for Vapor Coefficient
You can specify a multiplier to be applied to the local vapor phase heat
transfer coefficient calculated in the program.
 PlateFin: Pressure Drop Multiplier
You can specify a multiplier to be applied to the frictional pressure gradients
calculated in the program. The single multiplier is applied to liquid, two-
phase, and vapor pressure changes as required.
 PlateFin: Velocity Heads Lost in Inlet Nozzle
You can specify the number of velocity heads lost in the inlet nozzle (or stub)
of the exchanger. This loss relates to expansion from the nozzle into the
header.
 PlateFin: Velocity Heads lost in Outlet Nozzle
You can specify the number of velocity heads lost in the outlet nozzle (or
stub) of the exchanger. This loss relates to contraction effects in flow into the
nozzle from the header.
 PlateFin: Mixing between X-passes
In PlateFin, there is no option explicitly to specify mixing between passes in a
multi-pass crossflow exchanger. Mixing depends on the exchanger geometry.
Mixing will occur if the turnaround is in an external header between passes,
but will not occur if the turnaround is internal, using angled finning.
See also:
Layer Element Type
 PlateFin: Velocity Head Loss between X-passes
In a multi-pass crossflow exchanger, you can specify the loss between passes
in terms of the number of velocity heads lost. Velocity heads are based on an
average of the values in the finning before and after the header.
 PlateFin: Simple UA: pressure varies with:
The simple UA value for an exchanger is the heat load divided by the mean
temperature difference between hot and cold streams. Since stream
temperatures depend not only on enthalpy (heat load) but also pressure,
some assumption must be made about how pressure varies between the inlet
and outlet. This assumption often has little effect on the result, but can be
important for two phase streams, particularly single component streams,
when hot to cold temperature differences are small.

Three options are offered for pressure variation:

· with Temperature
· with Enthalpy
· Program: pressure varies with temperature when a stream is not the
only one of a given type (hot or cold), but with enthalpy if it is the only hot or
cold stream

For a more detailed explanation, see UA values.

Note that the real (calculated) UA value for an exchanger is based on
individual stream heat curves, not composites, and on the actual pressure
variation of that stream in the exchanger, not some artificial assumption.
The first two options for Simple UA pressure variation are new in PlateFin
V7.3. The third option is what was used in previous versions and in the MUSE
program. Variation of pressure with enthalpy is the assumption behind UA
values in HYSYS.
The simple UA value is important in Design calculations, which are based on
the composite hot and cold stream curves used in simple UA calculations.
For Simulation and Checking calculations, the UA method is used for the
composite curves which initialize the main calculation but should not affect
the final result. For reference purposes, however, in addition to the
real(calculated) UA value, two simple UA values are output (in the Solution
Overview) , one corresponding to the initial duty, and one to the final duty.
 PlateFin: Precalculated Coefficients
PlateFin does not use Precalculated Coefficients, which was a technique
used in MUSE to speed up calculations. Arrays of heat transfer coefficient and
pressure gradients were pre-evaluated, and then interpolated during the main
calculation, avoiding the need for time consuming recalculation of these
parameters every iteration.
In PlateFin, there is normally a full calculation of all heat transfer and
pressure drop parameters, every iteration, at every point. There is however
an option to limit these recalulations to speed up calculations, should this be
necessary.

See also:
Update Coefficients
 PlateFin: Preset Delta T for Boiling
Boiling coefficients depend in part on the stream to wall temperature
difference (delta-T). You can specify that a specific delta-T be used in
calculating boiling coefficients, rather than the difference between local
calculated values of wall and steam temperature.
 PlateFin: HTC (obsolete MUSE options)
This input provides an option to continue using some of the (boiling) heat
transfer methods used at one time in the MUSE program, but superseded in
later versions of that program.
The main alternative, Option 1, is the equivalent of the method switched on
in MUSE by specifying a two-phase heat transfer coefficient value of -1.
Basically, this reverts to a Chen-type convective boiling coefficient as used in
MUSE prior to version 3.30. This is an option identified in the Help text for
MUSE.
The other alternative, Option 2, is the equivalent of setting a coefficient of -2
in MUSE. This uses the current method for boiling coefficients, which includes
both nucleate and convective components, but limits the convective
enhancement associated with boiling on serrated fins.
The options are provided to help provide continuity for those who used these
options in MUSE.
 PlateFin: Calculation Options
The Calculation Options section includes the following screens:
Calculation
Convergence
Flow Maldistribution
 PlateFin: Calculation
The Calculation screen includes the following inputs:
Longitudinal Conduction
Heat Transfer in Distributors
Create Debug Output
Create PSF or MUI Output File
Points for Saved Wall Temperatures
Number of Load Split Points
Distance to Load Split Points
 PlateFin: Longitudinal Conduction
Longitudinal conduction relates to axial transfer of heat in the exchanger
metal – primarily in the parting sheets – from the hot to the cold end of the
exchanger. This effect is normally relatively small, but in some cases,
particularly in exchangers going down to liquid hydrogen or liquid helium
temperatures, it can be significant.
You can select whether or not longitudinal conduction should be allowed for,
and what components of the exchanger metal contribute to longitudinal
conduction. Fin metal is more likely to contribute if plain perforated or wavy
fins are used, since they offer a more complete axial conduction path than
serrated fins.
 PlateFin: Heat Transfer in Distributors
Distributor fins normally have a lower fin frequency than main fins, and the
flow is in many cases restricted to only part of the finning, although mass
fluxes will be higher than in main heat transfer finning. Also, importantly, the
overlap between the distributors of hot and old streams might be limited.
PlateFin can make allowance for all of these effects, in part rigorously, and in
part using estimations.
Given the complexity of distributor heat transfer, it is common to ignore it in
exchanger calculations and treat it as a margin on performance. If you wish to
do this, you can specify that heat transfer should be ignored.
 PlateFin: Create Debug Output
This item can be used to generate debug output or a design trace. Both are
currently created only as temporary files in the temporary directory. Neither
is normally needed and should be created only if so advised by AspenTech.
 PlateFin: Create PSF or MUI Output File
This item generates a PSF file or an MUI file.
The PSF file contains the process and properties information in the current
PlateFin case. It is created in the same directory and with the same name as
the current case, but with the extension PSF instead of EDR.
PSF files can be imported into any other HTFS (EDR) program, using File |
Import.
An MUI file is the input file for the heritage MUSE program for plate-fin heat
exchangers. Since PlateFin can open (import) an MUI file, the capability to
generate an MUI file for use as input to MUSE facilitates cross-checking the
two programs, and data transfer between organizations when one only has
MUSE, and the other only PlateFin.
MUI files are created in the same directory and with the same name as your
current case, but with the extension MUI instead of EDR.
Since PlateFin can handle more geometrically complex exchangers than
MUSE, there might be inconsistencies between the PlateFin and MUSE cases.
It is worthwhile checking that areas and number of layers for each stream are
as expected.
MUI files can only be generated for axial flow exchanger, not crossflow
exchangers.
 PlateFin: Points for Saved Wall Temperatures
This item relates to Layer by Layer calculations, when the temperature of
every layer wall (that is parting sheet / separating plate) is determined at
every point along the exchanger. In an exchanger with hundreds of layers,
and hundreds of calculation sheets per layer, this is potentially a very large
amount of information, and could dominate the size of the stored case file.
For this region, wall temperatures can be saved at a restricted number of
points along the exchanger. At each of these points, they are saved for every
layer.
The table of saved wall temperature is shown on the Results | Calculation
Details | Wall Temperatures | Saved Wall Temperatures tab. There are
also graphical representations of the temperature, on two subsequent tabs.
Plots along Length graphs the wall temperatures for a selectable set of
walls. Plots across Pattern shows temperatures for all walls, at a selectable
set of points along the exchanger.
Walls are numbered so that Layer N lies between walls N and N+1
 PlateFin: Number of Load Split Points
This input relates to the information presented under Layer Heat Loads in the
Thermal performance output.
Knowing the heat load in each layer of a given point is important when
designing a plate-fin exchanger. When selecting a layer pattern, not only
must there be a good mix of hot and cold streams, but hot layers with a high
load should usually go next to cold layers with a high load. Failure to do this
will result in unwanted temperature gradients across the exchanger.
However, this balance must be achieved not only for complete layers, but also
for parts of layers along the length. Output of load per layer is therefore also
provided for a three or more parts of the layer length. You can select how
many split points you want to use. If you specify three split points, the
exchanger will be divided into four parts along its length, and load per layer
information provided for each part.
You can also specify the location of the split points, in the table below this
input.

See also:
Distance to Load Split Points
 PlateFin: Distance to Load Split Points
Output information on Heat Load per Layer is provided for a set of regions
along the exchanger. These regions are defined by a set of Split Points. See:
Number of Load-Split Points.
The location for these split points can be specified using this input table.
Default values are found by splitting the main heat transfer region into
approximately equal length regions (using the number of split points
specified), but also by adjusting these regions so that split points coincide
with significant distances along the exchanger, such as points where streams
enter or leave.
Having run the program using the default values of the split points, you can
observe the calculated loads per layer, and also the temperature and heat
load profiles for each stream, and then adjust the split points and re-run if
you wish. The split point locations do not affect the overall calculated results,
just the set of values output in the Layer Heat Load tables.
 PlateFin: Convergence
The Convergence screen includes the following inputs:
Maximum Number of Iterations
Convergence Tolerance - Heat Load
Convergence Tolerance - Pressure
Relaxation Parameter
Calculation Grid Resolution
Convergence Criterion
Maximum Step: Heat Load
Maximum Step: Thermosiphon Flow
Maximum Iterations in Preliminary Checking
Calculation Steps across Exchanger
Update Coefficients

You can use these input to control the detail of the calculation grid, and the
way a calculation converges. This can be useful when the default settings do
not lead to full convergence. These options do not apply to Design
calculations, which use an entirely different solution algorithm.
See Also:
Calculation Control
 PlateFin: Maximum Number of Iterations
You can specify the maximum number of iterations to be performed.

See Also:
Calculation Control
 PlateFin: Convergence Tolerance - Heat Load
You can specify the required convergence accuracy of the overall exchanger
heat load.
See Also:
Calculation Control
 PlateFin: Convergence Tolerance - Pressure
You can specify the required convergence accuracy of the outlet pressure of
any stream.
See Also:
Calculation Control
 PlateFin: Relaxation Parameter
The relaxation parameter determines how fast the calculation converges, but
for exchanger where the duty is close to the maximum possible value for each
stream, large values can lead to instability in the calculation, and failure to
converge. Very low values can lead to convergence apparently being achieved
before it actually has.
See Also:
Calculation Control
 PlateFin: Calculation Grid Resolution
The grid resolution determines the number of calculation steps used. Steps are
selected internally to ensure good overall coverage of the exchanger and also
to ensure there is a very small step spanning any axial change, such as a
stream entering or leaving, or a transition from distributor to main fin. Results
are output for each calculation point, so you will see how many steps are
actually used. The grid resolution lets you increase the total number of steps –
with a potential increase in calculation time.
Increasing the grid resolution might be useful for exchangers with multiple
stream entry/exit points along the exchanger, particularly if these are being
simulated under non-design conditions, where there can be rapid changes in
temperatures as streams enter at temperatures different from those generally
applying at their inlet location. Increased resolution can also help convergence
for complex exchangers with multiple draw-on / off points along their length.
For a standard axial flow exchanger, there is a one-dimensional grid along the
exchanger. For a crossflow exchanger, there is a two-dimensional grid. For any
specified grid resolution, the number of grid points along the exchanger is
lower for crossflow exchangers, but the total number of points in the grid is
significantly higher, than in the corresponding one-dimensional grid.
See Also:
Calculation Control
Calculation Steps across Exchanger
 PlateFin: Convergence Criterion
Normally the calculation will stop once it is determined to have converged, but
you can specify that it continues beyond convergence. This may be useful in
giving you confidence that not only have the stream outlet conditions fully
converged, but also the stream temperature profiles along the exchanger.
See Also:
Calculation Control
 PlateFin: Maximum Step: Heat Load
You can specify the maximum permitted change in heat load per iteration.
This can have the effect of making the calculation converge more smoothly in
the early stages of an iteration when discrepancies from the true solution are
large.
See Also:
Calculation Control
 PlateFin: Maximum Step: Thermosiphon Flow
If you specify a thermosiphon calculation which requires calculation of the
thermosiphon stream flowrate to match a specified driving head, then after an
first calculation with the initially specified flowrate there is a further iteration
to find the correct flowrate. This input item can be used to determine the
maximum change in thermosiphon flowrates. If you initial estimate is a good
one, then a relatively small change in flow per iteration will be acceptable and
assist with computational stability. If you are unsure if your estimate is good,
try doing a series of fixed flow calculation, to evaluate the additional
resistance, or increase in head need to achieve your specified flow.
 PlateFin: Maximum Iterations in preliminary
Checking
Prior to any Simulation calculation, a checking calculation is performed. This
should establish temperature profiles along the exchanger which provide an
improved starting point for the subsequent simulation. This does assume,
however, that your initial estimate of stream outlet temperatures is not too
far from the final solution.
If this is not the case, then the preliminary Checking calculation could be
counterproductive. If you suspect this may be the case, you can specify a
limited initial number of checking iterations, to reduce or even eliminate the
preliminary checking stage.
 PlateFin: Calculation Steps across Exchanger
For a crossflow exchanger, you may explicitly specify the number of
calculation steps across the exchanger. The default value, which depends on
the Calculation Grid Resolution, and on the Number of Crossflow Passes,
should normally be used first, to establish whether there is any case for using
a different value.
Grid points are defined along the left and right hand sides of the exchanger,
and equally spaced between these points. There is thus one grid point per
crossflow step, with all the steps having equal width, except for half-width
steps along the left and right hand sides. This contrasts with the axial grid,
where grid point locations are adjusted to match the presence of layer
elements.
See Also:
Modeling Axial Flow Exchangers
 PlateFin: Update Coefficients
The calculation of heat transfer coefficients, pressure gradients, and related
parameters can account for a significant fraction of the total calculation time,
particularly for calculations on large numbers of layers, or with large two-
dimensional grids in crossflow exchangers. When a large number of iterations
is being undertaken with relatively small changes in the stream conditions at
each point from iteration to iteration, then the differences in calculated
coefficients from iteration to iteration can be very small.
For this reason, options are given for how frequently the coefficients should
be updated. These options only apply in Layer by Layer calculations for
standard axial flow exchangers, and for crossflow exchangers, and only to the
final set of iterations. For stream by stream calculations in axial flow
exchangers, whether this is the main calculation or a pre-cursor to layer by
layer calculations, coefficients are always updated every iteration. The same
applies in all preliminary checking calculations.
The default is to update every 10 iterations. The option of Every iteration
can be selected, as can the reduced frequency of every hundred iterations.
The value of the reduced frequency can be that calculation stability can be
much improved, at the expense of a loss (usually small) in accuracy of
calculated heat transfer coefficients. The option of Never recalculating
coefficients is the most extreme form. This means that coefficients etc are
calculated only on the first iteration of the final set. Preliminary calculations
will usually have set up a reasonable approximation to the solution at this
point.
 PlateFin: Flow Maldistribution
The Flow Maldistribution screen includes the following inputs:

Flow Distribution Calculations

Flow Distribution Specification

Balance Flows for Stream (not yet in use)
Flow Excess (%) in first layer
Flow Excess (%) in last layer
Total Specified Layer Flow
Stream / Flow table

These options are only available with Layer by Layer calculations.

To access any of the other calculations you must first set Flow Distribution
Calculations to Yes.

There are then three options for Flow Distribution Calculations, which
determine which of the other inputs are used.
· Flow Distribution: % Excess
· Flow Distribution: All Layers
· None

Each of these options is selectable independently for any stream. The None
option leaves the flow for a stream uniformly distributed amongst its layers.
Note that only flow distribution at inlet can be specified. If there is a
redistributor, redistributed flows are assumed to be uniformly distributed.
 PlateFin: Flow Distribution Calculations
With Layer by Layer calculations, you can specify a flow distribution among
the layers for one or more streams in order to investigate what effect this has
on thermal performance.
To do this, you must first set the input Flow Distribution Calculations to
Yes.
In the simplest specification, the flow distribution is presumed to be related to
pressure changes in the inlet and outlet headers and to the location of the
nozzles connected to them. The distribution is assumed to have a
characteristic form according to the sequence of layers coming off the header.
This can be a linear variation from one end of the header to the other, or a
symmetric (parabolic) variation about the center of the header, or some
combination of the two.
Flow distribution is thus specified by entering the percentage of excess flow
(relative to the mean) in the first and last layers fed by the stream header.
First means the first occurrence in the layer pattern as specified. If only the
excess in the first layer is specified, the default for the excess in the last layer
is the negative of this value, indicating a linear variation of layer flow
(superficial mass flux) with the sequence number of each layers connected to
the header. The distribution does not depend on the sequence number in the
overall layer, just the sequence number among layers connected to the
header.
If the first and last layers are specified as having the same % difference from
the mean flow, for example -10%, then a parabolic distribution is assumed, so
that midway between the two extreme layers, the flow must have an excess
of +5% relative to the mean.
The alternative method of specifying flow distribution all layers lets you
enter the (relative) flow at inlet in all the layers of any stream. You do not
actually have to specify this flow in every layer of the stream. If you only
specify the relative flow in some layers, the program defaults to uniform
distribution of the remaining flow among the unspecified layers.
There is not at present any prediction of pressure changes within the headers
or any adjustment of flows to achieve a pressure balance. It should also be
noted that this calculation refers to flow (mal)distribution among layers. It
does not relate to flow maldistribution across the width of individual layers or
to flow maldistribution among multiple cores in parallel.
When a header is feeding layers of more than one type, then by default, the
flow is assumed to be distributed to give uniform superficial mass flux along
the layers. That is to say that allowance is made for any difference in layer
heights. Any specified Flow Distribution is assumed to be superimposed on the
default distribution.
The flow distribution relates to layers connected to the inlet header. If a
stream is redistributed, the flow coming from the redistributor header is
always assumed to be uniformly distributed.

See also:
Flow Distribution Specification
Flow Distribution: % Excess
Flow Distribution: All Layers
 PlateFin: Flow Excess (%) in First Layer
For any stream, you can specify a non-uniform flow distribution among the
layers connected to the stream’s inlet header. Specify the percent excess
relative to the mean flow. A negative value indicates a flow lower than the
mean flow.
First Layer means the first layer with the stream in the sequence specified in
the layer pattern.
For more information on the way the flow in each layer is determined, see
Flow Distribution Calculations.
 PlateFin: Flow Excess (%) in Last Layer
For any stream, you can specify a non-uniform flow distribution among the
layers connected to the stream’s inlet header. Specify the percent excess
relative to the mean flow. A negative value indicates a flow lower than the
mean flow.
Last Layer means the last layer with the stream in the sequence defined by
the layer pattern. With flow maldistribution, calculations are done for every
layer in the layer pattern. The uniform flow distribution assumptions, which
normally permit calculations to be done for just half the layers in a symmetric
pattern, will in general no longer apply.
For more information on the way the flow in each layer is determined, see
Flow Distribution Calculations.
 PlateFin: Results
Result Summary
Warnings & Messages
Recap of Designs
Overall Summary

Thermal / Hydraulic Summary

Thermal Performance
Pressure Change
Thermosiphons
Solution Overview

Mechanical Summary
Exchanger Diagram
Exchanger
Distributors and Headers

Calculation Details
Stream Details
Stream Properties
Temperatures and Qualities
Wall Temperature and Heat Loads
 PlateFin: Result Summary
The Result Summary section includes the following screens:
Warnings & Messages
Recap of Designs
Overall Summary
 PlateFin: Warnings & Messages
When you run PlateFin, you might see a number of messages in various
categories.
· Errors which either cause the program to fail to complete its run, or to
fail to generate useful results
· Warnings which indicate a possible problems that are often worth
investigating
· Notes/Advisory which give further information on what the program
has done

Errors and Warnings are further broken down into three categories:
· Input – associated with input you have provided
· Results – associated with the calculations subsequently performed
· Operation – associated with exchanger performance

Warnings and Messages are displayed on five tabs:

· Errors – includes all types of errors and does not appear if there are no
messages
· Input
· Results
· Operation
· All – collects all the contents of the previous tabs

Tab headings indicate how many messages in a given category have been
produced.
 PlateFin: Recap of Designs
The Recap page lists a set of key results each time you run the program.
Each run adds to the table. When you close a case, the results of the last Run
are saved so that the table always has one entry when you open the case
again. If the table becomes too large, you can delete results from selected
runs.
The table shows a set of key results defined by the program, but you can add
to the list of variables shown.
 PlateFin: Overall Summary
The Overall Summary gives a set of key results in two tables. The first table
relates to the overall exchanger and the calculation performed. The second
table displays results on a stream by stream basis.
The overall exchanger information focuses on exchanger size and will be the
primary interest after a Design calculation. The stream by stream table
includes information on stream heat loads and outlet temperatures, which are
the primary result of Simulation calculations. Some geometric information for
each stream is also included in the table.
An important parameter for each stream is the Area Ratio.
 PlateFin: Thermal Hydraulic Summary
The Thermal Hydraulic Summary section includes the following sections:
Thermal Performance
Pressure Change
Thermosiphons
Solution Overview
 PlateFin: Thermal Performance
The Thermal Performance section includes the following screens:
Streams
Temperature Details
Temperature Graphs
Fin Performance
Layer Heat Loads
Zig-zag Diagram
 PlateFin: Streams - Thermal Performance
The Streams table in the Thermal Performance output provides full
information on the inlet and outlet conditions of each stream, as well as the
heat load, and the heat load per layer.
There is also information on the minimum and mean stream to wall
temperature difference and the mean heat transfer coefficient and fin
efficiency.
Some outputs are not available in all calculation modes.
 PlateFin: Temperature Details
The Temperature Details table in the Thermal Performance output lists the
temperature of each stream at each calculation point along the exchanger.
For layer-by-layer calculations, these are temperatures derived from
averaged specific enthalpies over all the layers for the stream.
The temperature details values are the basis of the temperature graphs,
which provide an easier method of obtaining an overview of the data.
 PlateFin: Temperature Graphs
The Temperature graphs show the temperature of each stream at each
calculation point along the exchanger. The numerical values on which the
graphs are based are given in the Temperature Details table.
For Design calculations, the graphs will show only two lines, since all hot
streams are assumed to be at the same temperature at each point, as are all
cold streams.
In crossflow exchangers, three lines are shown for each stream,
corresponding to its temperature along the exchanger centerline and on the
left- and right-hand sides. For axial flow streams, the three lines each
represent a flow path. For crossflow streams, the lines are transverse to the
flow path and represent stream temperature contours across inlet and outlet
(the two sides of the exchanger) and in mid-exchanger. One line will normally
be flat, representing the uniform inlet temperature of a crossflow stream.
In axial flow exchangers, there might also be regions where the stream lines
are flat. These correspond to distributor regions in which there is no heat
transfer. Lines begin and end at stream inlet and outlet points. For side
entry/exit distributors, these points are halfway along the length covered by
the header.
Temperature profiles in multi-stream heat exchangers can be complex,
particularly when streams enter at a temperature significantly different from
the temperature of other streams of the same kind (hot or cold) at that point.
It is possible for hot streams to rise in temperature at certain points or for
cold streams to decrease in temperature.
Sometimes there are features shown in a temperature profile that are clearly
non-physical, such as hot streams falling below the coldest cold stream
temperature at a point, or vice versa. This can indicate that although stream
outlet temperatures have converged, further convergence internally is
needed. Rerun the calculation so it is set to continue to the maximum number
of iterations, rather than stop at outlet convergence.
 PlateFin: Fin Performance
This output screen displays the fin performance data used in the calculations.
For Simulation and checking cases where fin geometry and performance data
are input, it simply reflects what is on the corresponding input screen. Its
main benefit is in Design cases where no such input has been supplied.
 PlateFin: Layer Heat Loads
Layer heat loads are reported for a set of sections along the exchanger. In the
program options input, you can specify the number of sections and their
location along the exchanger. In general, to promote good heat transfer
among streams, it is useful to have broadly similar heat loads in each layer
type, insofar as this is practical.
The table initially shows, for each layer type, the total load in all layers of a
given type and the total load per layer in each type. It then shows how this
total heat load per layer is divided among the various sections of an
exchanger.
The table is based on a mean heat load per layer for each layer type and does
not account for differences among the layers of each type for a layer-by-layer
calculation.
The table indicates how heat load is distributed among the layers and along
the length of the exchanger for each layer. The values in the table are used in
generating the zig-zag diagram in the Thermal Performance output. If the
layers of the various types have very different heat loads per layer, it can be
difficult to achieve a good layer pattern. This applies even more so when one
layer type is dominant in one section of the exchanger, and a different layer
type is dominant in a different section.
 PlateFin: Zig-zag Diagram
The Zig-zag diagram is a traditional way of assessing a layer pattern. It can
be drawn up based on a specified (or calculated) duty for each stream,
without the need for more detailed calculations.
The Zig-zag is a plot of the cumulative heat load in all the layers up to a
given point in the pattern. Cold streams have a positive heat load and are
shown as increases; hot streams have a negative load and are shown as
decreases. Because hot and cold layers typically alternate, the plot goes up
and then down, forming a zig-zag line. When there is double banking, there
will be two adjacent ups or two adjacent downs.
Since different layer types will have different heat loads per layer, the size of
the ups and downs will be different, and the zig-zag may wander away from
the zero line on which it starts. A good layer pattern will keep the zig-zag line
as close as possible to the zero line. When a zig-zag line is persistently on
one side or other of the zero line, it means there is a heat imbalance with an
excess of heat load in one part of the pattern, and a deficit in another part.
This heat must be conducted via the fins, distorting both the stream and
metal temperature profiles from the ideal predicted by the common wall
temperature assumption. The temperature gradients through the layer depth
can lead to degraded performance, and more importantly, thermal stresses
which in extreme cases could threaten the integrity of the exchanger.
After a layer-by-layer calculation, the individual heat loads in each layer are
known, but the mean heat load per layer type is used, so the basis of the Zig-
zag is the same as for stream by stream calculations.
In addition to the main Zig-zag, a number of details graphs are shown,
applying the zig-zag concept separately to a number of equal length regions
along the exchanger. These can indicate potential problems that could occur
in certain parts of the exchanger length, even when in the main overall Zig-
zag the layer pattern appears to be good.
The Zig-zag is valuable as a simple graphical tool, but it should be
remembered that the Zig-zag simply provides an indication of when there
might be a problem with the layer pattern. It does not show how that problem
will manifest itself. For that, you should look at the results of a layer-by-layer
calculation.
 PlateFin: Pressure Change
The Pressure Change section includes the following screens:
Streams
Main Distributors
Other Distributors
Pipework Losses
Mass Fluxes
 PlateFin: Streams - Pressure Change
The Streams table in the Pressure Change output breaks down the stream
pressure change into components associated with the main fin and inlet and
outlet distributors, and it also separates friction, gravity, and acceleration
pressure changes.
 PlateFin: Main Distributors - Pressure Change
The Main Distributors table in the Pressure Change output breaks down the
stream pressure change into components associated with the extreme left
hand (LH) and right hand (RH) flow paths through the inlet and outlet
distributors.
It provides information on the main fin pressure drop (where left and right
hand paths are identical) and then gives the total left and right hand pressure
drop. Distributor structure means that there is inevitably a difference between
left and right hand paths of an individual distributor, but some effort is
normally made to have the inlet and outlet distributors compensating each
other, so the total left and right hand path frictional losses are as close as
possible.
The final entry in the table is a flag indicating whether there is a risk of side
to side maldistribution. This should be taken as an indicator, but is not
definitive, particularly when one of the distributors is centrally symmetric, or
there is a redistributor in the layer.
Note that the potential maldistribution here is side-to-side within a layer, not
to be confused with maldistribution among the layers of an exchanger – or
among parallel exchangers. Note also that the calculation simply points to a
risk of side-to-side maldistribution, but does not evaluate its effect.
 PlateFin: Other Distributors - Pressure Change
The Other Distributors table in the Pressure Change output breaks down the
stream pressure change into components associated with the redistributor and
corresponding intermediate distributor. There is no analysis of left or right
hand flow paths, since the flow is too complex to analyse on a simple
left/right basis.
 PlateFin: Pipework Losses
Pipework pressure loss information is provided when there is a thermosiphon
stream for which the geometry of the pipework connecting the exchanger to
the column has been explicitly specified. Losses are given at entry to and
within each element, alongside void fraction and flow pattern information for
outlet pipework.
 PlateFin: Mass Fluxes
The Mass Fluxes output is given in order of stream flow through the
exchanger, including nozzles, distributors and main fins. Distributor mass
fluxes are given for inlet and outlet and for both fin pads if a distributor has
two. Main fin mass fluxes are given for the fins adjacent to the inlet and
outlet distributors. Often there is a single main fin between inlet and outlet,
but different main fin fluxes will appear if there is more than one main fin or
if there is redistribution.
Alongside mass fluxes, the velocity and rho-V-squared in each nozzle is given.
Rho-V-squared is the product of stream density (homogenous density for two
phase streams) and velocity squared.
 PlateFin: Thermosiphons
The Thermosiphons section includes the following screens:
Thermosiphons Performance
 PlateFin: Thermosiphons Performance
Thermosiphon performance information provides information on pressure
losses around a thermosiphon circuit, together with information on flowrates
and quality (vapour mass fraction), and a recapitulation of the heights
specified for the thermosiphon in the input.
In a thermosiphon, the gravity pressure increase from the liquid surface in
the column to the exchanger inlet point provides the driving head that must
balance pressure losses in the inlet pipework, exchanger and outlet pipework,
together with any gravitational pressure decrease in the exchanger and outlet
pipework.
There are three thermosiphon calculation options:
1 Thermosiphon flowrate, flow resistances and driving head are all fixed. The
program calculates the pressure discrepancy (error) needed to achieve a
pressure balance around the circuit. The pressure error can appear at either
the exchanger inlet or outlet, depending on whether the exchanger pressure
calculation for the thermosiphon stream has taken inlet or outlet pressure as
fixed.
2 Thermosiphon flowrate is fixed, flow resistances driving head (level
difference) are given, and the program calculated the change in inlet
resistance needed to achieve the given flow. If the inlet resistance needs to be
reduced to zero, it then calculates the minimum additional driving head that
would be needed.
3 Flow resistances – or pipework causing these resistances - are fixed, as is
the driving head (level difference). The program calculates the flowrate that
will result.
Most of the table contents are relevant to all calculation modes, but some are
pertinent to certain modes only. The actual flowrate and the flowrate as input
will be different in the Find Flow calculation (calculation 3 above). The extra
inlet line pressure drop and extra height of liquid surface needed are specific
to calculation 2. The pressure error at inlet and outlet are important for
calculation 1 for which at least one error would be expected to have a
significant value. Errors are shown for all calculation modes, but they should
be small and simply represent convergence errors in other modes.
 PlateFin: Solution Overview
The Solution Overview section includes the following screens:
Convergence
Special Options
 PlateFin: Convergence
The Convergence output provides information on how well various aspects of
a calculation have converged. There are error and warning messages when
convergence has not been achieved or has not quite been achieved, so the
information in this output is supplementary. The detailed meaning of each
item can be seen at the bottom of the screen when focus is on that item.
The convergence table is not relevant to Design calculations, which use an
entirely separate calculation procedure.
To understand the convergence parameters, it is useful to understand the
basis of the calculation. A specific enthalpy and pressure value is established
for each point where a stream is present – in every layer type for a stream by
stream calculation, or in every layer for a layer-by-layer calculation. From
these are calculated the stream temperature and all other parameters, such
as heat transfer coefficients, heat flux and frictional and other pressure
gradients. The program then integrates the heat flux and the pressure
gradients for each stream. The specific enthalpy profile is revised by
averaging it with the integrated heat transfer, with the bias heavily towards
the existing profile. The pressure profile is simply replaced by the integrated
profile. Scaling or shift factors are incorporated into the update processes to
enforce the required end conditions, such as fixed inlet and outlet values in a
Checking calculation.
The overall convergence, reported in the output, is achieved when a stable
value to the required accuracy has been achieved for the total heat load
(simulation) or area ratio (checking). Heat transfer convergence relates to the
consistency between the stream enthalpy change from inlet to outlet and the
integrated heat transfer. To give a further measure of the convergence, the
worst discrepancy between enthalpy change and the corresponding integrated
heat transfer is also reported.
 PlateFin: Special Options
The Special Options output gives a summary of some of the key assumptions
incorporated into the calculation. Many of these items are input items (see
the relevant topics in the Input section of the PlateFin help), but some are
detailed outputs which apply to the exchanger, for example:
· The overall heat load for hot streams and cold streams (both input and
calculated values).
· UA values, both the (true) value of the calculated results, and two
Simple UA values, corresponding to the initially estimated heat load, and the
calculated heat load. Simple UA values are based on some nominal variation
of pressure with enthalpy, which can be specified under calculation options.
For more information, see UA values.
· For Layer-by-layer calculations:
– The maximum temperature difference between two streams in
adjacent layers
– The location where this temperature difference occurs (given as
the distance along the exchanger and as a calculation point)
– The two streams involved
– The layer number involved (the second of the pair of layers
concerned)
– The pair of adjacent layers involved, identified by the layer
number of the second of the two layers. (Layer number N in the output
thus implies that the maximum stream-stream temperature occurs between
layers N-1 and N.)
An overview of temperatures in all layers is provided in Results |
Calculation Details | Layer Temperatures. By default, these temperatures
are only output at a restricted set of locations along the exchanger, but you
can generate Layer Temperatures at all calculation points if temperature
differences other than the maximum need to be investigated.
 PlateFin: Mechanical Summary
The Mechanical Summary section includes the following sections:
Exchanger Diagram
Exchanger
Distributors and Headers
For Design calculations, the Mechanical Summary provides detailed
information on the exchanger that has been designed.
For other calculation types, most of the exchanger geometry has been
provided as input, either directly or shown as a default. However, the
Mechanical Summary shows some useful secondary information relating to
flow or heat transfer areas.
 PlateFin: Exchanger Diagram
The exchanger diagram shows the overall exchanger geometry. Right-click
the diagram to select individual layer types and view the layout of distributor
and other finning within that layer type.
The exchanger diagram in the output shows the results of a Design
calculation. For other calculation types, the diagram should be an exact
replica of the diagram shown in the exchanger input.
Diagrammatic information on the exchanger geometry is also provided.
Layer Pattern
Layer Occupancy
 PlateFin: Exchanger
The Exchanger section includes the following screens:
Overall Geometry
Stream Geometry
Fin Geometry
Layer Types

There is no table of Fin Performance data in the output. Normally, this would
just replicate the table in the input. To see the performance data for a Design
calculation where there is no direct specification of fins, save your file, then
select Update file with geometry under the Run menu. A Simulation
calculation for the selected Design then transfers the fin (and other)
geometry data to the input so that the corresponding fin performance data
can then be viewed in the input.
 PlateFin: Overall Geometry
The overall geometry is a table giving properties of the exchanger as a whole,
rather than of individual streams and layers. It shows the overall exchanger
size, total number of layers, and breaks the exchanger down axially into a
distributor region at each end, with a heat transfer region between them.
 PlateFin: Stream Geometry
The stream geometry table gives an overview of the geometry for each
stream. It analyses the exchanger into five lengths for each stream, with a
central main fin region, a distributor at either end (one nearer end A, another
nearer end B), and then additional lengths before and after the distributor.
When a distributor is on the end of the exchanger, the length before or after
the distributor will correspond to the endbar (sidebar) width.
The surface area of each stream is the total, based on the primary and
secondary area in each layer, including both distributors and main fin.
The inlet and outlet distributor types are given for each stream. More detailed
information on distributors is given in a separate table.
Finally, information is given about the main finning for each stream. If a
stream has multiple main fin types in a layer, the tabulated information
relates to the first fin type only.
Similarly, if a stream is present in more than one layer type, the information
in the table (other than the total area and number of layers) relates to one
specific layer type. Normally, the internal geometry at any point along the
exchanger will be the same in all layer types in which a stream is present, so
only showing the structure within a representative layer type should not be a
problem.
 PlateFin: Fin Geometry
The fin geometry table shows all the basic fin information provided in the
input, either as direct input or by importing from a fin databank. In Design
mode, it shows data for the fins that have been selected during the design
process. If any fins have been specified in the input and are required during
design, the table will show the specified fins, followed by any additional ones
selected during Design.
In addition to the primary geometry information, the following secondary
information is provided.
· The subchannel aspect ratio: subchannels are the flow areas between
fins. The aspect ratio is the ratio of the subchannel height (fin height minus
fin thickness) to the subchannel width, the distance between the surfaces of
adjacent fins.
· The Blockage fraction is the fractional difference in axial flow area
between an empty layer and a layer with fins.
· The Hydraulic diameter comes from the subchannel geometry, using
the normal definition based on flow area and perimeter, and approximating
the subchannel as a rectangle.
Note: The aspect ratio, blockage fraction and hydraulic diameter are key
parameters in the HTFS correlations for fin performance, friction factor and
Colburn j-factor. If you have access to the HTFS Research network, you can
find the exact equations used for these factors, as a function of Reynolds
number and fin type and geometry.
· The Flow area per unit width is a fundamental parameter of the
finning, which when multiplied by the internal exchanger width, gives the flow
area per layer.
· The Primary perimeter relates to the parting sheet area, excluding the
area at the root of the fins. The perimeter is an area per unit length (in the
flow (axial) direction). The perimeter per unit width is given, which is a
dimensionless quantity. It will normally be just under two, since a layer has a
parting sheet on each side.
· The Secondary perimeter per unit width is the equivalent parameter
for the fins. It is typically in the range of 5 to 10 for main fins, and 2 to 3 for
distributor fins, which have a lower fin frequency.
 PlateFin: Layer Types
The Layer Types form of the output replicates the Layer Types form in the
input. It is primarily of interest for Design calculations, when the Layer types
input is not used, and all the Layer types information is generated by the
Design process. Use the drop down selector to view the output for each layer
type in turn.
The Layer Type information generated by the Design calculation should be
valid for straightforward cases, but simplifying assumptions in the Design
process can mean that there might be inconsistencies in some cases. The
Layer Type table is the basis from which the Exchanger diagram in the output
is drawn, so if there are inconsistencies, they should be immediately
apparent, as should what needs to be done to correct them.
Sometimes changes can be made to the Design input, for example by
explicitly specifying certain distributor information be used in a Design, or by
enforcing an allocation of two streams to a given layer, or by prohibiting
redistribution. These are available under the Design Options input.
Alternatively, first save your case, then select Update file with geometry
under the Run menu. A Simulation case for the selected Design then
transfers the layer type (and other) geometry data to the input. You can then
edit the layer type information, changing the length of certain elements of
layer types, to move things up or down the exchanger.
 PlateFin: Distributors and Headers
The Distributors and Headers section includes the following screens:
Inlet Distributors
Outlet Distributors
Redistributors
Intermediate Distributors
Pipework
 PlateFin: Inlet and Outlet Distributors
There are separate tables for inlet and outlet distributors, with the same
information in each.
After information about the distributor type and header location comes the
basic size information dimensions a, the axial length, and dimension b. This is
followed by information on nozzles (stubs) and headers.
Next, the information on the distributor fins is given for pad 1, the pad
adjacent to the header. The code number for fin pad 2 is also given. In most
cases, this is the same as pad 1, so the fin information is not repeated.
The distributor surface area is base on the total area, primary plus secondary
surface, for the entire distributor which is assumed to be rectangular. It
includes regions within the distributor in which there is no flow. For simplicity,
it is based on the dimensions of the fin used in pad 1. This is an output
parameter only and is not used in the calculations.
The percentage area for heat transfer in the distributor is more important. It
is based on the superficial area of those parts of the distributor through which
there is flow, as a fraction of the total superficial area of the rectangular area
occupied by the distributor. For distributors on the ends of the exchanger, the
percentage area for heat transfer includes an additional approximate
reduction factor to allow for the limited overlap of hot and cold stream end
distributor areas.
 PlateFin: Redistributors
Redistributor information is provided when appropriate. The information is
similar to that for inlet and outlet distributors, but there can be three fin
pads. In a dividing redistributor, the main flow (i.e., the flow that remains
within the layer) flows first through pad 1, then pad 2. Flow leaving the layer
to go to a header flows through pad 3. Fin information is for pad 1, as the fin
types in all three pads are normally the same.
Surface area information is given separately for the main and header flows,
together with the percent area for heat transfer which is assumed to be 100%
on the basis that there is flow at all points in a redistributor, and being
located centrally with an exchanger, there will normally be another stream
with which it can exchange heat.
 PlateFin: Intermediate Distributors
Intermediate distributors are associated with redistributors. When there is a
redistributor feeding a redistribution header in one layer type, there will be
an intermediated distributor at the same location in another layer delivering
flow from the header to that layer type. The converse applies in a combining
redistributor, in which the intermediate distributor feeds the flow to the
header and the redistributor takes the flow from the header, mixing it with
the flow already in the layer.
An intermediate distributor is effectively identical to a side entry or side exit
distributor, except that there is no nozzle, as no flow enters or leaves the
exchanger at a redistribution point.
 PlateFin: Pipework
Pipework information is provided when there is a thermosiphon stream in the
exchanger, and the input defines the geometry of the pipework connecting
the exchanger to the column sump from which it is supplied and to which it
returns a partially vaporised stream. Information focuses on secondary
information, such as flow areas, derived from the direct geometry provided.
This table is not available with the first release of PlateFin.
 PlateFin: Calculation Details
The Calculation Details section includes the following sections:
Stream Details
Stream Properties
Temperatures and Qualities
Wall Temperatures
 PlateFin: Stream Details Overview
The Stream Details section includes the following screens:
Stream Details
Stream Plots
Layer Details
Layer Plots
 PlateFin: Stream Details
The stream details table gives a table of values of a range of parameters at
each of the calculation points along an exchanger where the stream is
present. Use the drop down list to select the stream you want. For each
stream, values are shown for that portion of the exchanger where the stream
is present.
In the Plots facility, any of the tabulated parameters for a stream can be
plotted against either the distance along the exchanger, or the cumulative
heat load for the stream.
Tabulated parameters shown include:
· Point number, its corresponding Distance from end A (the top). After
a Design calculation, the point numbers are not integers, but have the form
1.5, 2.5, 3.5, etc., since the details information is defined mid-way along each
step between the primary set of calculation points.
· The Stream and Wall Temperature – the wall is the parting sheet and
the temperature is that midway between its two surfaces.
· The Heat Load – a cumulative value from the stream inlet to the given
point.
· The stream Pressure and Pressure Change (from the stream inlet).
· The Vapor Mass Fraction (quality).
· The Heat Flux – based on the superficial area (the parting sheet area).
The local heat flux based on the fin primary and secondary area will be
smaller and will vary along the fin because of temperature changes along the
fin between the parting sheets at each point.
· The Heat transfer coefficient – a local value assumed to apply to both
the primary surface (parting sheet between fin roots) and the secondary
surface (the fins).
· The Effective heat transfer coefficient – the coefficient based on
parting sheet area, which is the fundamental area for heat transfer from one
layer to the next. It is equal to the local coefficient multiplied by half the sum
of the primary perimeter per unit width and the fin efficiency times the
secondary perimeter per unit width. The factor of one half arises because
there is a parting sheet each side of the layer. When applied to distributor
regions, it incorporates a factor equal to the useful fraction of the distributor
area at the point.
· The Fin efficiency - a correction factor multiplying the secondary
surface area and allowing for the fact that conduction along the fin at a point
means that the local fin-to-stream temperature differences are lower than the
main wall parting sheet-to-stream temperatures difference.
· The Conductance per unit length - the ratio of the heat load per unit
length to the wall-to-stream temperature difference at the point. This is equal
to the effective heat transfer coefficient multiplied by the total area per unit
length for the stream at the point. It is like a UA value, but it is for just one
stream and it is local, that is, per unit length, rather than applying to the
whole exchanger.
· The Pressure gradients, due to friction and gravity.
· Void fraction, for two phase streams.
· Liquid and/or Vapor Reynolds number, .as used in fin performance
calculations.
For a layer-by-layer calculation, the parameters shown are an average over
every layer at each calculation point within the exchanger. The wall
temperature is the average of all the walls (parting sheets) either side of
layers the stream. The two parting sheets either side of any layer will in
general be at slightly different temperatures.
For a stream by stream calculation, the values are an average over all the
layer types in which the stream is present. Normally the values for a stream
in all layer types will be the same, so the values shown are the actual values
used in the calculation. The only exception is in the unusual event of a stream
using a different fin type in the various layer types in which it is present.
At any given calculation point, the wall temperatures listed are the same for
all streams, since for a stream by stream calculation, the common wall
temperature assumption is used.
For Design calculations, at any point, all hot streams are at the same
temperature and all cold streams are at the same temperature.
The calculation points cover both distributors and main fin for each stream. In
the distributor region, with side entry/exit distributors, the calculation points
begin at (or close to) the mid-point of the inlet region, so the effective length
of the distributor is about half the full length. The parameters in the table are
adjusted to allow for the fact that the actual flow length and heat transfer
region of the distributor might not match the axial length implicit in the axial
length of the distributor.
When distributor heat transfer calculations are switched off, heat transfer
coefficients and fin efficiencies are still calculated for information purposes,
but the effective heat transfer coefficient, and hence the heat flux, is set to
zero, and the cumulative load does not change in that region.
 PlateFin: Stream Plots
You can plot Stream Details parameters for a selected stream along the
length of the exchanger. This plot can provide valuable insight into exchanger
performance. You also have the option to plot each parameter against heat
load instead of distance along the exchanger.
To examine any portion of the plot in more detail, click and drag to define a
rectangular area, then click the magnifying glass symbol.
To show the location of the calculation points used to generate the curve,
right click the plot, select Plotting Options | Data Series, change Symbol
from None to Cross, and drag the size to small.
After cross flow calculations, which are performed both along and across the
exchanger, the plots become a little more complicated.
Plotted parameters for axial flow streams appear as three lines, representing
values along the two sides and the middle of the exchanger.
For crossflow streams, the distance used in the plots is measured across the
exchanger. If there are multiple crossflow passes, a cumulative distance is
used, based on one exchanger internal width per crossflow pass. Passes
nearer end A appear near the left hand side of the plot, so that the axis
caption Distance from end A (which still appears for crossflow streams) is
still true in the broadest sense, even if the distance is not measured in a
straight line.
Crossflow streams are also plotted as three lines, representing the edges and
center of each crossflow pass. When there is a header between the crossflow
passes, the effect of mixing in the header is evident, since all three lines in
each pass will then begin at a common mixed stream point. When there is
internal turnaround, you can see how the flow nearer end A of one pass
transfers to be nearer end B of the next pass. The detailed geometry of
internal turnaround is approximated in the calculation by assuming each pass
spans the entire exchanger width and turnaround happens instantaneously at
the end of the pass.
Crossflow or multi-pass crossflow streams can also be specified within an axial
flow calculation. In such cases, plots involve one line, not three. Such a
stream is approximated as an axial flow stream, but its temperature is then
adjusted, so that it is uniform over a central crossflow region of each pass.
This effect can be seen in the temperature plots for these streams.
 PlateFin: Layer Details
The Layer Details table is produced for each stream after Layer-by-layer
calculations and focuses on the overall and outlet conditions for each layer in
which that stream is present.
Results presented include:
· Layer Number within the overall layer count and the corresponding
Layer Type.
· The Outlet temperature of each layer.
· The Relative head load in each layer relative to the mean for all layers
in which the stream is present from inlet to outlet.
· Pressure change from inlet: this includes the inlet nozzle and all
subsequent changes in main and distributor finning.
· Relative pressure loss: this includes only friction changes and relates
only to distributors and main fin. It does not include nozzle losses. This
relative loss gives a preliminary indication of the extent of any potential
thermally induced flow mal-distribution among layers.
· Inlet and Outlet flow: In many cases these two are the same, and the
same for all layers. Inlet and outlet flows will differ in any layers where there
is a re-distributor. Flows will differ among layers when flow mal-distribution
has been explicitly specified, and also when streams occupy more than one
layer type and these layer types have different heights.
 PlateFin: Layer Plots
The Layer Plots option lets you select how various parameters for any stream
vary from layer to layer. The parameters are
· Outlet temperature
· Heat load
· Inlet or outlet flows
· Pressure change - relative or absolute
The parameters are plotted as points for each layer where the stream occurs,
with lines joining the points.
Heat loads and outlet temperatures show how balanced the heat distribution
is among the layers in the pattern.
Pressure changes indicate whether there might be a risk of layer to layer flow
distribution.
Flows can indicate the form of any specified flow distribution. They can also be
of interest when there is re-distribution or partial draw-off.
This facility only applies to Layer-by-Layer calculations
 PlateFin: Stream Properties
In the Stream Properties output under Calculation Details, there are two tabs,
Stream Properties and Inlet and Outlet Properties.
On the Stream Properties tab, you can select a stream to see a table of the
properties of liquid and vapour phases, at up to 25 points. These are at 25
different pressure and temperature conditions, found by selecting from among
the calculation points for the stream.
The property values are found by interpolating the initially provided tables of
stream physical properties. They are only likely to provide information
significantly different from that in the input tables when both pressure and
temperatures change significantly for a stream.
On the Inlet and Outlet Properties tab, there is a single table giving liquid
and vapour properties for each stream, at its inlet and outlet from the
exchanger. The set of properties displayed is the same as on the Stream
Properties tab. The inlet and outlet values will be very similar to values at
the first and last points on the first tab; any differences are due to pressure
changes in the stub/nozzle/header region.
 PlateFin: Temperatures and Qualities Overview
The Temperatures and Qualities section includes the following screens:
Temperatures and Qualities
Temperature and Qualities Plots
Layer Temperatures
Plots across Pattern
 PlateFin: Temperatures and Qualities
The temperatures and qualities (vapor mass fractions) table is intended
primarily for use with layer-by-layer calculations.
Values in the table are derived by analyzing the temperature and quality
profiles along all the layers of a given layer type and reporting the maximum
and minimum values over all the layers of a given type, as well as the
average temperature and quality.
After a stream by stream calculation (Simulation or Checking), only mean
values appear in the table, since the calculation is based on a single
evaluation of each layer type rather than separate evaluations of each layer
of each type.
Also tabulated are the temperature and quality ranges, that is the difference
between the maximum and minimum values at each point. With a good layer
pattern, such difference will usually be relatively small.
The two other tabulated parameters are the maximum (absolute) wall to
stream temperature difference and the maximum wall-wall temperature
difference. These are parameters sometimes used to assess risks to exchanger
performance and strength.
The temperature and quality tables are on a layer type basis, not stream
basis, so if there are multiple streams within a layer type, the tabulated
values will apply to different streams at different points along its length.
 PlateFin: Temperatures and Qualities Plots
A table of stream temperature and quality parameters is given for each layer
type, at every calculation points along the exchanger. Values include the
mean over all layers of the selected type, and the maximum and minimum
value.
The Plots facility gives a graphical overview of how the various parameters
vary along the exchanger and can provide an easy way to understand the
exchanger performance and spot any problem areas.
This facility only applies to Layer-by-Layer calculations.
 PlateFin: Layer Temperatures
The layer temperatures table provides the stream temperature within every
layer of the exchanger at a set of points along the exchanger. This set of
points can be selected as an input under Calculation Options. Output at every
point along the exchanger can be specified if required. It is the same set of
points as is used for wall temperatures in the Saved Wall Temperatures
output.
The stream temperatures in every layer are provided for the benefit of users
who wish to apply their own further analyses to such data. Elsewhere in
PlateFin, there are other outputs based on an analysis of Layer Temperature
data. The maximum of the stream-to-stream temperature difference in
adjacent layers is provided in the Solution Overview, Special Options output.
The Temperatures and Qualities output table identifies the maximum and
minimum stream temperatures at every point along the exchanger.
 PlateFin: Plots across Pattern
A set of stream temperatures and qualities is saved for every layer at a set of
calculation points along the length of the exchanger. It is the same set at
which wall (parting sheet) temperatures are stored for display on the Wall
Temperatures output screens. The number of such points can be selected in
Options | Calculations.
The plots facility lets you see how stream temperature varies from layer to
layer across the entire layer pattern at a series of calculation points along the
length of the exchanger. You can select which of the stored points should
appear as a line on the graph by changing a value in the table at above the
plot. Deleting values in the table will let you see fewer lines on the graph.
This facility only applies to Layer-by-Layer calculations.
 PlateFin: Wall Temperatures
The Wall Temperatures and Heat Loads section includes the following screens:
Wall Temperature Range
Wall Temperature Range Plots
Saved Wall Temperatures
Saved Wall Temperatures Plots along Length
Saved Wall Temperatures Plots across Pattern
 PlateFin: Wall Temperature Range
The wall temperature range table is relevant to layer-by-layer calculations
and is found by assessing the walls (parting sheets) for all the layers of all
types at each calculation point.
The primary assessment is of the minimum and maximum wall temperature,
along with the wall temperature range (maximum minus minimum) and the
wall numbers with the maximum and minimum wall temperatures. The wall
number is the sequence number of the layer to the left of the wall. Thus wall
7 lies between layer 7 and layer 8. The zeroth wall is the cap sheet preceding
the first layer.
The final three columns assess the wall-wall temperature difference across
each layer, and display the following:
· The maximum value
· The number of the layer at which the maximum occurs in the layer
pattern sequence
· The type of that layer, expressed numerically, with 1 meaning layer type
A, 2 meaning layer type B and so on.
Wall to wall temperature differences lead to thermal stresses across fins, so it
is important to know the maximum value of this parameter. In this table, the
maximum value over all layers is reported. The maximum value for individual
layer types is reported in the Temperatures and Qualities table.
 PlateFin: Wall Temperature Range Plots
Parameters in the Wall Temperature Range table can be plotted as a
function of distance along the exchanger. A range of options are available. For
example, it is possible to show how the maximum, minimum, and mean wall
temperatures vary along the length of the exchanger. This can indicate, for
example, if there are regions within the exchanger that may contribute
particularly to thermal stressing.
This facility only applies to Layer-by-Layer calculations.
 PlateFin: Saved Wall Temperatures
This table is available after Layer-by-Layer calculations. It gives the
temperatures of every wall (parting sheet) in the exchanger at a set of points
along the exchanger. If there are N layers in the exchanger, there are N+1
walls. Wall 1 is the parting sheet (cap sheet) adjacent to the first layer in the
layer pattern.
The number of points along the exchanger at which wall temperatures are
given is determined by the value of the input for Number of saved wall
temperatures on the Calculation Options | Calculation tab.
The amount of information in the table can be large, so the Plots along Length
and Plots across Pattern provide a useful way of displaying the wall
temperature information.
 PlateFin: Saved Wall Temperatures Plots along
Length
The plots of wall temperature along the exchanger length display information
in the Saved Wall Temperatures table. Information is provided at a set of 11
layer-walls (parting sheets) approximately equally distributed across the
pattern. These walls are listed in a one line table above the graphics. By
changing any of the wall numbers in this table, you can change what is
plotted. If you want to display a temperature for a reduced number of walls in
the plot, set values of zero in the one-line table, to suppress the unwanted
lines.
 PlateFin: Saved Wall Temperatures Plots across
Pattern
The plots of wall temperature across the layer pattern display information in
the Saved Wall Temperatures table. The temperature of every layer-wall
(parting sheet or cap sheet) is shown at a set of points along the exchanger.
It is normally good practice to have a more or less uniform wall temperature
across the exchanger.
These points at which layer temperatures are plotted are listed in the small
table above the graphics. Both the line number in the Wall Temperatures
table and the corresponding calculation point number are given. By changing
any of line numbers in this small table, you can change what is plotted.
 PlateFin: Getting Started Overview
This exercise leads you through the procedure to design a simple single-phase
heat exchanger using Aspen PlateFin. The Design calculation will determine
the size of the exchanger.
You can access the Help file at any time by clicking an item and pressing F1.
Contents:
Problem Definition
Physical Property Data
Running the Case - Design mode
Reviewing the Results – Design mode
Creating a Simulation Case
Running the Case - Simulation mode
Reviewing the Results – Simulation mode

Launch the program from either the shortcut or the AspenONE Tool bar.
Select PlateFin from the New tab and click OK.
Proceed to:
Problem Definition
 PlateFin: Problem Definition
The first item to change is the units. From the Program Toolbar, select from
the Units drop-down box and change the units to SI.

The Application Options screen determines the type of calculation to be

performed and the Number of Streams. Set the Calculation Mode to Design,
and check that the number of streams is 2. Other items can all be left at their
default values.
You will see that some of the options are grayed out and some have red
values. Values are grayed out when they are not appropriate to a particular
calculation. Red values indicate program defaults. As you proceed with input,
the red and grayed out values might change.
The Process Data for this example is listed below.

Fluid Units Hot Side Nitrogen Cold Side Nitrogen

Total Flowrate kg/s 20 20

Temperature (In/ Out) °C 120 / 20 10 / 110

Operating Pressure
bar (abs) 5 10
(absolute)

Allowed pressure drop bar 0.4 0.4

Proceed to:
Physical Property Data
 PlateFin: Physical Property Data
On the Stream 1 Composition screen, you can select one of the databases.
Select B-JAC, since this is the simplest to use, although for more accurate
properties, high pressures, or complex mixtures, Aspen Properties or
COMThermo would be better.
Type nitrogen in the component list. For all other composition parameters,
defaults can be used.

On the Stream 1 Properties screen, click Get Properties. You will see a set of
properties generated at various temperatures. The Pressures fields in the
Pressure Level group show the pressure to which the set of properties relates.
Selecting the other pressure displays a second set of properties.
Repeat to set properties for nitrogen for stream 2.
Proceed to
Running the Case - Design mode
 PlateFin: Running the Case - Design mode
Because our example is a Design case, no geometry needs to be entered.

Click Run.

Proceed to
Reviewing the Results
 PlateFin: Reviewing the Results
The Results section becomes available after the run is complete.
The Results Summary includes any calculation messages, a Recap of
previous runs, and an overall summary of the Exchanger, both overall and on
a stream by stream basis.
Further details are provided within the Thermal/Hydraulic Summary,
Mechanical, and Calculation Details sections.
Look at each of the tabs in these sections. Some have no output because they
do not apply to Design mode. The temperature graphs show the temperature
profile of each stream along the exchanger. The Exchanger Diagram shows
the exchanger that has been designed. Right-click the diagram and you will
see the structure of the various layer types used in the Design.
Proceed to:
Creating a Simulation Case
 PlateFin: Creating a Simulation Case
The exchanger design can now be converted into a Simulation or Checking
case.
From the Run drop-down menu, select Update file with geometry.
On the Applications Option screen, the Calculation mode will now be set to
Stream by Stream Simulation. It would be possible to change to Checking,
which requires the same input data.
Look at the Process data input. You will see that all the stream inlet
conditions are now specified, alongside the heat loads used for the Design.
Look at the various geometry input screens. You will see the exchanger
geometry has been specified.
Look at the exchanger diagram in input. You will see it is the same as the one
viewed previously with the results.

Proceed to:
Running the Case - Simulation mode
 PlateFin: Running the Case - Simulation mode
Click Run.

Proceed to:
Reviewing the Results
 PlateFin: Reviewing the Results - Simulation
Mode
Look at the Overall Summary. For each stream, notice the heat load and
percentage of specified heat load. You will see that the percentage is just over
100. This is because the exchanger Design used a default margin of 10%
additional area.
The results can be printed out or exported to Excel.
The individual tables in the output screen can be copied to the clipboards and
pasted in another application. Click the desired table, then right-click to
display a menu. Select Copy or Copy with description, then paste into a
suitable application.
 Plate-fin Heat Exchangers Overview
In a plate-fin exchanger, the process streams pass between metal plates
which are held together by corrugations (fins) which provide extended
surfaces and also enhance the heat transfer coefficient. The edges of the
plates are sealed by side bars. The material of construction is typically
aluminum but stainless steel and nickel alloy units are well established in the
aircraft industry are now entering the process industry.
Plate-fins are susceptible to blockage by particulate matter and it is
recommended that filters should be placed at the inlet of such units to remove
particles greater than 0.3 mm diameter. Design pressures up to 90 bars can
be accommodated, depending on size and operating temperature. Single units
up to 1.2 m X 1.2 m X 6.2 m are manufactured in aluminium and units up to
0.6 m X 0.6 m X 2m are manufactured in stainless steel. Multiple units can be
produced by manifolding.
See also:
Corrugations
Headers and Distributors
Redistributors
 PlateFin: Corrugations
The fins in a plate-fin exchanger hold the separating plates apart to form a
flow channel. The thickness of the fins and the plates depends on the pressure
requirements. There are a number of fin types.
· Plain Fin – this is the simplest type of fining and has similar pressure
drop and heat transfer characteristics as a small bore tube. Any combination
of standard sheet thickness and fin density can be made.
· Plain-Perforated Fin – metal strip is perforated and then corrugated to
form fins. This type is important in boiling applications as it helps to maintain
a wetted surface. It can also be used to improve distribution by forcing the
fluid to flow through the perforations instead of along the fins. Any
combination of standard sheet thickness and fin density can be made.
· Serrated Fin – sometimes known as lanced, offset strip, or interrupted
fins. This type of fin has short lengths of fin alternately offset by about half-a-
fin spacing. This gives enhanced heat transfer at the expense of enhanced
pressure drop. The serration length is typically 0.125 inches or 3.2 mm,
although fins with longer length serrations, such as 12.5mm, are also made
by some manufacturers. Serrated fins are only made in aluminum for medium
or low thickness fins. Serrated fins are often used in air separation plants
where high thermal effectiveness with low mass velocities are required.
· Herringbone Fin – sometimes known as Wavy fins. This is a smooth fin
which has a wavy pattern impressed on it, regularly along the flow direction.
The wavelength is typically 10mm, and the wave amplitude is typically the
same as the fin spacing. This fin is used mainly with hydrocarbons where high
mass velocities are required. It should be noted that this fin type is not
available from all manufacturers. Some prefer the long wavelength serrated
fin as an alternative.
Many different fin types can be used at different points in a PFHE, which is
one reason why this type of exchanger offers great design flexibility. Each
stream will use a main heat transfer fin and a distributor fin of the same
height. The same fins will be used in all the layers of a stream, but sometimes
different fins are used at different points along the exchanger length.
In specifying the geometry of a plate fin heat exchanger, each fin is identified
by a number. The geometry of each fin must be specified. Performance data
for each fin is also needed.
 PlateFin: Headers and Distributors
Each layer of a plate-fin heat exchanger contains a length of main heat
transfer fining covering the entire exchanger width and running axially along
the exchanger. At each end of the main heat transfer fining there is a
distributor, consisting of pads of fining laid at an angle and directing the flow
between the main fining and a gap in the side bar or end bar providing access
to the exchanger for the process fluid.
Headers are welded on to the side or end of the exchanger to distribute the
fluid to or collect it from the many layers carrying the flow each stream.
Nozzles are welded on to each header for connection to external pipework.
Distributors are usually made of perforated fining, with a relatively low fin
frequency.
Hardway distributors are made of either serrated or perforated fining.
Optional program input is available for identifying the geometry of the inlet
and outlet distributors and nozzles for each stream and the fins used in each
distributor. Distributors contribute to the pressure drop of each stream in an
exchanger. They can also contribute a small amount to the heat transfer, but
this is normally neglected and treated as a safety margin.
 PlateFin: Hardway Distributors
Hardway distributors (or redistributors) comprise a section of perforated or
serrated fining laid transverse to the main fining in an exchanger. This offers
a very high resistance to flow along the exchanger, but low resistance to
transverse flow. Hence transverse flow entering (or leaving) the exchanger is
well distributed across the exchanger.

Hardway Redistributors are useful for achieving partial draw-off of a stream,

as the fraction drawn off can readily be varied.
PlateFin has special methods for the pressure drop in the hardway direction
for hardway distributors. No corresponding method for hardway heat transfer
exists. For flow across the exchanger, normal fin methods for the relevant
(perforated or serrated) fin are used.
Hardway distributors are modeled as mitered side entry distributors, with flow
along the exchanger in one pad and across it in the other. Flow across the
exchanger is modeled by normal flow along the fins. Flow along the
exchanger (in the hardway direction) uses the special model, which is that
every time the flow goes through a perforation (or the gap between
serrations), it loses one velocity head, as it would in going through a normal
orifice. This model has the advantage that it requires only the perforation
area and not the number and size of the perforations.
 PlateFin: How to Use the Program
This section provides advice on various aspects of achieving the best from
PlateFin.
Achieving Convergence
Area Ratios and Checking
Design Calculations
Distributor Calculations
Modeling Axial Flow Exchangers
Numbering Grid Points
Optimization of Design
Specifying Crossflow Exchangers
Specifying Multipass Crossflow
Specifying Thermosiphon Reboilers
 PlateFin: Achieving Convergence
PlateFin contains a range of facilities for controlling the convergence of the
iterations of Simulation and Checking calculations. Normally the default
values of these parameters should provide an adequate solution, and in the
Status window during a run, you will see the convergence being achieved in
the various stages of the calculation. In full these are:
· Initialization based on composite hot and cold stream temperatures
· Preliminary checking calculation
· Stream by stream simulation
· Layer by layer calculation
The results of each calculation stage provide the basis for starting the next
stage. The calculations proceed as far as is required by the main calculation
type. The status window records the extent of convergence after various
preset numbers of iterations. If a calculation fails to converge, you will be
able to get a feel for the stage at which the problem occurs. If the final stage
converges, it is not important that an earlier stage has not completely
converged.
The following guidelines for may be useful for achieving convergence.
1. If a layer-by-layer calculation does not converge, revert to a stream-by-
stream calculation and make changes to ensure that calculation converges. It
is unusual for a layer-by-layer calculation to fail after a stream-by-stream
calculation has succeeded. If it does happen, try increasing the maximum
number of iterations.
2. If a stream-by-stream calculation fails, look at what has happened in the
preliminary checking calculation. Sometimes, if the initial estimates of outlet
conditions are poor, the preliminary Checking can hinder, rather than help,
the main calculation. If the preliminary checking is diverging, set the
Maximum number of iterations for preliminary checking to one (not
zero) to eliminate any problems caused during preliminary checking.
3. If a Checking calculation has a problem or you want to investigate further
why a preliminary Checking is hindering a Simulation, then switch the
calculation mode to Checking and set the maximum number of iterations
(overall) to one. The calculation will still fail, but the temperature profiles
reported will be those of the initial estimate, normally coming from a
composite hot or cold stream curve. You might be able to see that a stream is
entering or leaving at a location inappropriate to its specified inlet or outlet
temperature, which can indicate an error in the exchanger geometry
specification or an inappropriate initial estimate of outlet conditions.
Correcting any such problems will often help a lot.
4. A related set of problems can occur when the flow of one stream in the
exchanger and its contribution to the exchanger heat load are minuscule
relative to all the other streams. Convergence can be improved by setting the
flow direction of such streams to No flow so they do not participate in the
calculation. Such streams will exit at the mean wall temperature at their exit
point, while ignoring them will have minimal effect on the calculated
performance of the rest of the exchanger.
5. If a Simulation is still not converging after you have performed the previous
steps, you might need to reduce the convergence parameter, to 0.05, 0.02, or
even 0.01. Reducing the convergence parameter might require more
iterations, but it is best to not to change both together. Only increase the
number of iterations when the results in the Monitor window indicate that
convergence is occurring, but slowly. Remember that a reduced convergence
parameter might help prevent divergence resulting from poor initial estimates,
but it will also decrease the rate at which convergence is achieved and could
potentially lead the program to assume that convergence has occurred when it
has not. (There are a number of measures of convergence reported in the
output, so if this happens it will be evident.)
6. Another control on convergence is provided by reducing the Maximum
step: heat load. Sometimes this can help prevent divergence in initial
iterations without the need for a large reduction in convergence parameter.
7. If a calculation reports convergence, but examination of the Solution
Overview (Thermal Hydraulic Performance output) indicates that aspects of the
convergence are unsatisfactory, two things can be done. One is to reduce the
required convergence accuracy. The other is to change from Stop when fully
converged to Continue to maximum iterations – optionally with an
increase in the maximum number of iterations. This will help resolve case
where low convergence parameters are causing spurious indications of
convergence.
8. Convergence is sometimes difficult to achieve in exchangers with a very
tight (small fraction of a degree) internal temperature pinch. There is an input
under the Thermal Analysis input called Heat transfer area factor, which
normally defaults to unity. Specifying a lower value of this parameter might
give a converged solution. You can experiment to find the highest value of the
parameter which gives convergence. With a tight internal pinch, the parameter
will often not change the stream outlet temperatures significantly (you can
investigate this), so a valid solution for stream performance may be obtained
through the temperature profile along the exchanger, and the length of the
long flat region at the pinch may not be entirely accurate.
 PlateFin: Area Ratios and Checking
Checking calculations and the area ratios they produce is new to PlateFin.
Area Ratios are output for all calculation types. For Design calculations, they
are the familiar area margin, but for Checking and Simulation more
explanation is required.
Area Ratio is a fundamental concept used for shell and tube and other simple
two-stream exchangers, but requires some care when applied to multi-stream
(or even two-stream) plate-fin exchangers.
The Area Ratio is the ratio of the actual exchanger area to the area required
to achieve a given duty. Simplistically, the purpose of a Checking calculation
is to determine an Area Ratio, while for a Simulation calculation, the Area
ratio is expected to be unity at convergence. There is normally only one Area
Ratio defined, since there is a single definition of Area (based for example on
the outside surface area of tubes) which applies to both sides in a shell and
tube exchanger, and the (absolute value of the) duty of the two streams is
the same. There is also an implicit assumption that any one bit of exchanger
area is as good as another.
For plate-fin exchangers, all these assumptions can be called into question.
Each stream has a separate area and a separate duty, so that a separate Area
Ratio needs to be defined for each stream. Some weighted average can of
course be defined for the entire exchanger, but the exact meaning of such an
average is unclear in anything but simple two-stream cases.
Another complication is that because different fins can be used, the area of
one stream is entirely unrelated to that for any other stream. This can be
mitigated by basing the areas used for area ratios on the parting sheet area
and incorporating local fin secondary and primary areas and fin efficiencies
into the definition of an “effective heat transfer coefficient.” This is done in
PlateFin.
A further difficulty is how the “actual area” is defined. Should it include
distributor area? Should it include regions of the exchanger where either hot
or cold streams are absent, so there can be no heat transfer from one to the
other? What if there is significant heat transfer from one hot stream to
another in such regions? What if there is only one stream present at a point,
but it is a layer by layer calculation, and there is heat transfer among layers
at different temperatures?
To avoid such complexities, the simple assumption is made in PlateFin that
the definition of “actual area” is as inclusive as possible and includes all points
where calculations are performed, even if for assorted reasons, there is no
heat transfer at such points. There is thus area which must be accounted for
as actual area, but in the absence of heat transfer, it is not accounted for as
required area. The result is that fully converged Simulation calculations can
have Area Ratios above unity. When distributor heat transfer is switched off,
large area ratios will be particularly evident.
There is an entirely different issue associated with very tight temperature
pinches. A significant amount of exchanger area may be accounted for by
such pinches, which can result in an exchanger being very well converged on
all measures, except for area ratio. In such cases, low area ratios (for
example between 0.9 and 1) may be of much less concern than such values
would be for other types of exchanger.
 PlateFin: Design Calculations
To perform a Design calculation, it is best to start at the simplest level, at
which you specify just the required inlet and outlet conditions for each
stream. If you are unsure about what maximum pressure drop to specify,
work initially with the program defaults. You will see in the results what
fraction of the maximum pressure drop is used for each stream, and then you
can re-run with revised maximum pressure drops.
The “first shot design” will give you an initial indication of how big the
exchanger needs to be. It will also reveal if there are any problems with the
specified process conditions and where the temperature pinch in the
exchanger is. The Design process can accommodate a small discrepancy
between the hot and cold stream loads, but you may wish to eliminate any
such discrepancy before proceeding further.
The first shot design might reveal the need for multiple exchangers in
parallel, or even multiple exchangers in series. Be cautious with design
requiring multiple exchangers in parallel; a good manufacturer might be able
to use significantly fewer. The maximum size constraints are normally
determined within the program and are conservative relative to what a
number of manufacturers can achieve. The limits used are reported in the
output, but the option exists of explicitly specifying these limits in the input.
Exploring the effect of relaxing (increasing) the limits may be useful.
For such exchangers with a very large thermal duty, you can also explore the
effect of explicitly specifying the number of exchangers in parallel, rather
than letting the program try to find an optimum.
If the program fails to find any design that meets the maximum size, heat
transfer, and pressure drop solutions, it will revert to a single exchanger
which will probably breach the maximum length and/or depth constraints.
For exchangers with a very long thermal duty, accommodating the duty in a
one block in series might be impractical whatever Design improvements are
made. In such cases, specify an artificially long maximum length, to assess
what might be required. Then, using the very long design as a guideline, split
the exchanger duty into two (or more) blocks, making the break at a stream
inlet or outlet point partway along initial the exchanger if possible. Use the
results to determine the conditions of all streams at the split point(s). Save a
copy of the file for each series exchanger, reset the inlet and outlet conditions
for each stream appropriately, and design each of the exchangers again.
When a stream is only present in one of the series blocks, you can simply set
its flow direction (under Process Options) to be “no flow” in the exchanger
where it is not present. This avoids any need to renumber or re-order any
streams in the exchangers.
If there are features of an initial design which are inappropriate, you can
repeat the Design with an explicit specification of what you want for these
features. This could be a header location or distributor type, an exchanger
width or number of exchangers in parallel, or a specific number of layers for
one or more streams. All these options are specified in the main geometry
input.
The Layer Type input is not used in Design mode, but equivalent information
is available under Design Options. You can explicitly specify a main fin type to
be used, or indicate whether or not streams should be redistributed, or appear
in the same layer as another stream. If you want to force use of a particular
fin type, but want the program to determine its detailed geometry, then
specify a fin number of -1,-2,-3, or -4 to force use of plain, perforated,
serrated, or wavy fin respectively.
There is a Design Option input to select what geometry input is used. By
default, all specified geometry is used, but there are alternatives of switching
off some or all of this input when doing a Design.
When a satisfactory Design has been achieved, you can select “update file
with geometry” to create a Simulation case based on the Design. In general,
the predicted heat load will be larger than that required of the Design for
several reasons. The Design calculation by default incorporates a margin of
10% (see Area scaling under Design Options input). In complex exchangers it
is often necessary to overdesign certain streams, to ensure that other
streams achieve there required duty. Simulation calculations can include
allowance for heat transfer in distributors, while Design calculations do not.
(You can elect not to include distributor heat transfer, if you wish, just as you
can put in a smaller or larger margin in Design.)
In complex exchangers, you should check that the required heat load is
achieved for all streams, not just most streams. Required load will normally
be achieved, but the Design process involves a number of simplifying
assumptions, and it is possible that the more realistic Simulation calculation
could reveal potential problems.
Most importantly, remember that PlateFin produces a “first shot” Design, and
that what a manufacturer would produce will at best be different in detail, and
in some cases can be significantly different in size, particularly if you use an
unrefined Design based on process data only. Manufacturers will use their
own fin geometries and fin performance data, which might differ from the EDR
defaults. They also have extensive experience in how to achieve the best
design. PlateFin provides many options for the experienced designer to use,
together with facilities which can help operators and plant designers
understand the effects of, and reasons for, particular exchanger Design
decisions.

See Also:
Optimization of Design
 PlateFin: Distributor Calculations
The distributors at the inlet and outlet of each layer consist of one or two
pads of finning, at least one of which is at an angle to the main flow direction,
to direct the flow in the main fin to or from the stream header.
Each distributor pad has a defined fin type and flow direction, so the mass flux
(perpendicular to the flow direction) is well defined. This means that pressure
gradients and heat transfer coefficients can readily be calculated for each pad,
using Reynolds number, friction factors, and Colburn-J factors. Since the pads
are (usually) triangular, they have two extreme flow lengths, one along one
side of the triangle, the other (at the vertex) being zero. The mean pressure
change in each pad is calculated using a mean flow length. The pressure
changes along the extreme (left and right) paths are used in determining the
risk of flow maldistribution.
Pressure changes in distributors
The total pressure change in a Distributor is determined from the frictional
loss in each pad, the loss associated with turning and the change in flow area
at the inlet to and outlet from the distributor, and between the pads, if there
are two of them. The pressure change in distributors is thus calculated
rigorously using this method in all calculation modes. Gravitational changes
are included when appropriate.
Heat transfer in distributors
Heat transfer in distributors is a calculation option in simulation/checking
modes; by default it is on. The calculation grid in these modes includes any
Distributor-only region at the ends of the exchanger. Heat transfer in
distributors is not allowed for in Design Mode. The calculation grid here covers
only the heat transfer region of the exchanger.
In Simulation/Checking, there is a single axial grid along the exchanger. Each
stream is assumed to enter the calculation grid at one specific point. For an
end entry or exit distributor this point will be the first or last on the axial grid.
For a side entry/exit distributor the entry/exit point is assumed to be half-way
along the side-bar entry gap. The axial flow length of the distributor on the
calculation grid is thus typically half the real distributor length for these
cases. This distinction is allowed for in allocating distributor pressure loss and
enthalpy change to points in the distributor region.
For heat transfer calculations, the mass flux between the inlet and outlet of
the distributor is assumed to change uniformly with axial distance along the
exchanger. This approximates the physical situation in which there is a step
change in mass flux between the distributor pads, but the change happens at
different axial locations, depending on the transverse location across the
exchanger. All distributor heat transfer calculations assume that the two
distributor pads use the same finning. This is usually the case, but when it is
not, it means that heat transfer calculations are making an approximation
that pressure drop calculations do not.
Distributor heat transfer depends not only on heat transfer coefficients, but
on two area factors: the fraction of the (rectangular) distributor region
occupied by active distributor finning, and the extent to which the active
finning in one distributor overlaps with the active finning in other layers. The
first of these is readily evaluated for each distributor. The second, overlap
with other layers, is harder to determine, so an approximation is used. Local
heat transfer coefficients in distributors are first converted to coefficients
based on parting sheet area (with the normal allowance for fin efficiency and
primary and secondary fin area) and then further multiplied by an area factor
to give effective distributor heat transfer coefficients. The area factor varies
from unity at the point where the distributor fin and main fin meet, to a
lower, or even zero value at the overall stream inlet or outlet point.
In the stream details output, the actual and effective heat transfer coefficients
are tabulated and each can be plotted as a function of length along the
exchanger. It is often seen that local distributor coefficients get higher
towards the overall stream inlet and outlet points (because of the higher mass
flux there), but the effective coefficients get smaller, because of the reducing
area factor.
When distributor heat transfer is switched off, local heat transfer coefficients
in the distributor are still calculated, but the effective coefficients are set to
zero. It is straightforward to evaluate the effect of distributor heat transfer,
by running the case with and without this heat transfer switched on.
Crossflow exchangers
Distributors can be specified for axial flow streams in crossflow exchangers. In
this case there is a two dimensional grid covering the exchanger. Distributors
are, however, modeled using the same assumptions as for pure axial flow.
The distributor heat transfer and geometry is averaged across the distributor
width. The effective heat transfer coefficient is thus essentially the same for
all transverse locations. No allowance is yet made for distributor area being
concentrated on one side of the exchanger, or for there being components of
both axial and transverse flow within the distributor.
 PlateFin: Modeling Axial Flow Exchangers
Standard axial flow exchangers use a one dimensional grid of calculation
points along the exchanger length. The number of points is determined
indirectly via the grid resolution input (low/medium/high/very high) on the
Calculation Options | Convergence tab.
Grid points along the exchanger are not all equally spaced, but have locations
adjusted according to the items defined axially along each layer type. A
notional set of “fixed points” is first set up, based the transition point from
one layer item to another. Their distances from end A are all rounded to the
nearest mm.
A set of calculation points is defined within each interval between these fixed
points. These are located 1mm after the fixed point at the beginning of the
interval, and 1mm before the fixed point at the end of the interval. Other
calculation points within the interval are equally spaced between the fixed
points. The number of points in each interval between the “fixed points” can
vary in each interval, but the selection is based on getting an approximately
uniform distance between points along the exchanger. In some special
circumstances, extra calculation points are added to particular locations. At
the extreme ends of the exchanger, the calculation points are located on the
fixed points, rather than 1mm away.
The same grid of calculation points is used for each layer type in the
exchanger.
In the detailed results output, calculation points are numbered from end A,
and the distance from end A to each point is given.
If you want to see the location of calculation points on graphical outputs, you
can right-click a line to get plotter options, and change the point option from
none to cross.
It is possible to model crossflow streams, with single or multiple passes, when
a Standard Axial Exchanger is specified. These still use an axial flow grid, but
the temperature at axial points within each pass is artificially made to be
uniform. The mass flux used for calculating heat transfer coefficients and
pressure gradients of such crossflow streams is based on the crossflow
geometry.
The temperature uniformity approximation used for crossflow streams should
be reasonably good in single pass crossflow streams with little temperature
change, or for multi-pass crossflow streams with a large number of crossflow
passes.
It is appropriate to use this approximation for modeling crossflow streams
when the majority of the heat exchange comes from axial flow streams. In
other situations, specify one of the crossflow options under Exchanger Type.

See also
Modeling Crossflow Exchangers
Exchanger Type
 PlateFin: Numbering Grid Points
In a Standard Axial Flow Exchanger, the calculation grid points are
numbered sequentially from end A.
In a Crossflow Exchanger, there is a two dimensional calculation grid. Each
of the points is allocated a number in the calculation output. Points are
counted from end A, first down the left side, then further axial sets, moving
across the exchanger. Point 1 is on the left side at end A, the final point is on
the right side at end B.
Imagine a grid of 20 points axial by 5 points across the exchanger. The
calculation point numbers would be

End A

1 21 41 61 81
2 22 42 62 82
3 23 43 63 83
.....
.....
.....
18 38 58 78 98
19 39 59 79 99
20 40 60 80 100

End B

The number of points on the calculation grid will often be larger than this
example.
Because the number of grid points with crossflow can be large, output is not
provided at every calculation point. The general philosophy is to supply the
extreme points and middle points of each axial or crossflow pass.
Temperature profiles along the exchanger are output in the Thermal
Performance / Temperature Graphs, and the corresponding Stream
Temperatures table. The data tabulated and plotted relate to three sets of
points along the exchanger length, along the extreme left and right sides, and
along the middle of the exchanger. In the above example, this would
correspond to points 1-20, 41-60, and 81-100.
Temperature profiles for axial flow streams will be broadly similar to those in
axial flow exchangers, except that there will be three lines instead of one. The
output would actually be produced in the order 1-20, 60-41, 81-100 to
simplify the plotting.
The temperature profiles for crossflow streams are also given for the same set
of points as for axial flow streams. The difference is that the profile for a
crossflow stream does not represent the change along its flow direction, but
across it. When a crossflow stream enters from a header (main or
intermediate), it will have a uniform temperature across the corresponding
axial length of exchanger. This will appear in the left or right hand set of
points, according to the crossflow header location. Although the lines
corresponding to the left, central, and right profiles appear in the same color,
with a little thought it is usually obvious which line is which. Inspection of the
point numbers in the corresponding table can provide further clarification if
needed.

In the Details output for axial flow streams, the Stream Details plots, and the
corresponding data tables, use the same points as described above for the
axial flow streams.

For crossflow streams, the Stream details plots use different points,
corresponding to the top (near end A), middle, and bottom lines across the
exchanger in each pass. When plotted against distance from end A, this
distance is interpreted as the cumulative distance along the crossflow flow
path. If a stream has five passes, in an exchanger 400mm wide, then the
distance axis will span from 0 to 2000mm. This will apply whatever the
straight axial distance from end A to B, and whatever the fraction of this
straight axial length is occupied by each pass.
When there is a single crossflow path, there is no net flow towards either
exchanger end. The term distance from end A is still used, although
distance across exchanger might be more appropriate.
When there is a crossflow header between passes, it will be apparent in the
temperatures of the crossflow stream shown under stream details. The three
lines for a stream will start at the same temperature as they enter from the
main inlet heater, but the lines will then diverge, corresponding to different
conditions at the top, bottom, and middle of each pass. At the intermediate
header, the flows across different axial locations will be mixed, and the
temperatures of the three lines will coincide as they enter the next cross flow
pass and then begin to diverge again.
Under Stream Details, it is usually simpler to look at the graphical output
than to interpret the corresponding tables. The set of points used for plots is
given in the Stream Details tables. The set of points chosen for crossflow
streams can appear to be rather complicated. It is not usually important to
understand which point is which, but the information is as follows.

In the above example, if the twenty points along the exchanger represented a
single crossflow pass, with the inlet on the left hand side the points plotted
would be:
1,21,41,61,81 representing the top of the pass,
90,70,50,30,10, representing the middle of the pass, and
21,41,61,81,101, representing the bottom of the pass.

If the 20 axial points in the example represented two crossflow passes, in

overall downflow, with 9 points in the first pass and 11 in the second, then
the points used in the table and plots would be.
1,21,41,61,81 representing the top of the first pass, with left to right flow,
85,65,45,25,5, for the middle of the pass, then
9,29,49,69,89 representing the bottom of the first pass.
These would be followed by
90,70,50,30,10, representing the top of the second pass, which has right to
left flow,
14,34,54,74,94 for the middle of the second pass, and then
101,81,62,41,21 for the bottom of the second pass.
 PlateFin: Specifying Crossflow Exchangers
Crossflow exchangers have axial flow streams and crossflow streams. Axial
flow streams flow from end A to B (or B to A) and are defined in exactly the
same way as in Standard axial flow exchangers. When specifying a Layer
Type, the standard sequence for an axial flow stream is:

Endbar
Inlet distributor
Main fin
Outlet distributor.
Endbar

For B-A flow, the inlet and outlet distributors are interchanged. There can be
multiple streams along the length of each layer, separated by end bars.
If the Exchanger Type is simple crossflow then there are only two streams,
and the axial streams cannot have distributors. The layer type specification is
as above, but the axial length of the distributors is zero, and the distributor
type is header only.
Crossflow streams are assumed to flow from left to right or right to left across
the full width of the exchanger (left and right are defined viewing the
exchanger with end A at the top). When specifying a Layer type, a simple
cross flow stream has a sequence such as:

Endbar
X-flow main inlet
X-flow fin
X-flow main outlet
Endbar

The X-flow main inlet and outlet have zero axial length in the layer type
definition. Their size is deduced from the X-flow fin axial length. The X-flow
main inlet and outlet identify the stream number and by implication the
“distributor” number. Crossflow streams do not have distributors, so the
distributor type (under Distributors input) must be header only, with the
only required input under Distributors being the side of the exchanger, left or
right, on which the header is located.
Kettle reboilers are a special type of crossflow exchanger; selecting this
exchanger type means the program automatically sets appropriate defaults,
including a thermosiphon-like calculation of flow to balance the pressure head
of liquid. Like simple crossflow exchangers, they just have two streams, but
unlike simple crossflow exhangers, the axial flow stream (the condensing
stream) can have distributors.
See also:
Specifying Multipass Crossflow
Exchanger Type
 PlateFin: Specifying Multipass Crossflow
Multiple crossflow passes can be defined in a number of ways. If the passes all
have the same length, the simplest way is to specify:

Endbar
X-flow main inlet
Multipass X-flow: fin
Multipass X-flow: number of passes
X-flow main outlet
Endbar

For flow from B-A, the inlet and outlet would be interchanged. This implies
“internal turnaround” with short triangular regions of axial flow fin linking the
crossflow passes.
An alternative, with internal turnaround is to specify:

Endbar
X-flow main inlet
X-flow fin
X-flow fin
X-flow fin
X-flow fin
X-flow main outlet
Endbar

Each fin represents a different pass and a change of crossflow direction. This
specification of a sequence of X-flow fins is useful when the passes are of
different axial length or use different types of fin.
A third way of specifying multiple crossflow passes is used when there are
intermediate headers connecting the passes. Imagine a layer with three such
passes, with overall downflow. The Layer Type sequence would be:

End bar
X-flow main inlet
X-flow fin
X-flow pass outlet header
End bar
X-flow pass inlet header
X-flow fin
X-flow pass outlet header
End bar
X-flow pass inlet header
X-flow fin
X-flow main outlet
End bar

The main inlet and outlet define the stream number, and “distributor
number”. The Distributors input specifies Header only and requires the side
of the exchanger with the header to be specified. The pass inlet header refers
to blind (nozzle-less) headers. These are given numbers, which are relevant
only in the unusual event of multiple layer types linked by such headers.
There is a fourth crossflow configuration which cannot yet be modeled by
PlateFin, nor by its predecessor MUSE. In this confituration, each layer has a
single axial or crossflow pass, but different passes occupy different groups of
layers in the layer-stack.

See also
Specifying Crossflow Exchangers
Modeling Crossflow Exchangers
Exchanger Type
 PlateFin: Specifying Thermosiphon Reboilers
One stream in an exchanger can be specified as a thermosiphon reboiler,
meaning that its flow rate is driven by a head of liquid.
To specify the thermosiphon stream, the stream type under Process Options
must be set to Thermosiphon rather than simply hot or cold.
The layer type and other exchanger geometry information is specified for the
thermosiphon stream in the same way as for other streams, but certain
additional information is required on the Thermosiphon input page. Most
important are the heights of the liquid level (in the column) and the height of
inlet to the exchanger. The difference in these heights gives the liquid head
driving the flow. The absolute value of each is not important, so the heights
can be given relative to any convenient reference level. If the reboiler is
internal to a column, only these two heights are needed. If the reboiler is
external to the column (in other words, connected by pipework), then the
height of the two-phase return line to the column is also needed. An estimate
is often fine, as its effect on the calculated result is often small.
Two options are available for dealing with the pipework: one is to specify in
full detail the pipework components in the inlet and outlet lines. The other is
to make an estimate of the percentages of the driving pressure head that are
lost in each line. There are defaults for these percentages, giving typical
values, but you can specify alternative values if you wish.
The Thermosiphon type input lets you specify either an internal reboiler (no
pipework), an external reboiler with estimated pipework losses (percent of
driving head), or an external reboiler with fully specified pipework.
When pipework is specified, various piping elements such as bends and
straight lengths can be specified, together with a general element for which
the number of velocity heads lost can be specified. For the outlet line, which
is usually relatively short, any components should be specified in flow order.
For the input line, order is less important, and a line with multiple bends can
be specified by indicating a total length of line and a then a total number of
bends – set Number in series to the number of bends. Pipework manifolds
are not specified explicitly, but the Number in parallel can be specified for
each piping element, and each time this changes, the presence of a manifold
is assumed and inlet losses to the element downstream of the manifold are
set accordingly.
There are three calculations that can be performed for a thermosiphon. This
option is selected on the same page as thermosiphon geometry input. The
simplest calculation has the flowrate and pipework resistance fixed. The
pipework losses are calculated, but in general there will not be a pressure
balance around the thermosiphon circuit. Pressure inconsistencies at the
exchanger inlet and outlet are reported. It often makes sense to use this
simple thermosiphon mode first, to check that the specified pipework losses
are plausible.
The second thermosiphon calculation also has fixed flow, but it iterates to
determine the change in inlet resistance needed to balance the pressure
around the thermosiphon circuit, that is to make the sum of the pressure
losses in the exchanger and pipework, together with any gravitational
pressure decrease in the exchanger and outlet pipe, equal to the pressure
increase, or head, in the inlet line.
The final thermosiphon calculation option is to take the resistances in the
inlet and outlet pipework as specified, and to evaluate the flowrate of the
thermosiphon stream needed to achieve a pressure balance.
When simulating a two-stream thermosiphon reboiler, you should normally
set the hot (condensing) stream to have some required outlet condition (such
as complete condensation) and set its Simulation revision option (on the
Process Options tab) to Flow rate. Note that the Simulation revision option
for the thermosiphon stream itself should be left set to the default value of
Outlet temperature. Any flow iteration on the thermosiphon is external to
the Simulation loop.
Thermosiphon calculations are normally performed using a stream by stream
simulation. Layer by layer calculations are not normally appropriate, because
of the limited range of temperatures found in most thermosiphon reboilers.
Layer by layer calculations are only possible using the simplest thermosiphon
options, with fixed flow and resistance. This may be useful if the
thermosiphon stream is a small part of a more complex exchanger.
Thermosiphon calculations can be performed using Checking mode, but this is
only likely to be appropriate with the simplest thermosiphon calculation.
Iterations to find a flow or inlet resistance change are usually of dubious
value when the exchanger inlet and outlet conditions are artificially fixed, as
in Checking.
The special thermosiphon input and other calculation facilities are not
available in Design mode. If you want to design a thermosiphon, specify an
exchanger inlet pressure that includes allowance for submergence, and
specify a thermosiphon stream flowrate and exit quality consistent with the
required load, then design as for any other exchanger.
 PlateFin: Optimization of Design
PlateFin can design a plate-fin heat exchanger with multiple streams. You
only need to specify the stream inlet and outlet conditions and stream
properties. The program will perform a ‘first shot’ thermal design of the
exchanger. It selects appropriate fin types and determines the number of
layers of each stream and the overall size of the unit. Distributors, nozzles,
and headers are also designed in outline. If necessary, multiple exchangers in
parallel will be specified. Allowance is made for mechanical design
considerations where these impinge on the thermal design.
A full design of a plate fin heat exchanger can only be undertaken by
manufacturers, who have proprietary data for their own fins and who will also
perform a full mechanical design. PlateFin is intended for use by those who
wish to explore various options for using plate fin exchangers at an early
stage in a process design.
Information must be provided on stream inlet and outlet conditions, flowrates,
and heat loads, but any of these items may be omitted if the program has
sufficient information to deduce it from other input.
There is no need to specify any geometric data when running a Design
calculation. However, you can specify that specific fins are used, or you can
pre-set some of the geometric parameters and leave the program to calculate
the remainder.
If you specify geometry data, you should use the geometry data switch under
the Options menu to control which data the program will use.
PlateFin is aimed primarily at designing brazed aluminum plate fin heat
exchangers. It uses the same Design logic as the PFIN engine in the precursor
program, MUSE. The manufacturers association, ALPEMA, provided useful
advice as PFIN was written. Stainless steel and titanium plate-fin heat
exchangers can also be designed, but care should be taken with defaults, such
as those for maximum block dimensions, for which the default values relate to
aluminum exchangers.
See also:
Assessing a Design
Improving a Design
Design Failures
 PlateFin: Assessing a Design
The Design calculation gives a ‘First Shot’ design only. The more complex the
exchanger is, the greater the chance that an experienced engineer will be
able to improve on the design. For any exchanger with more than two
streams, there is also always the possibility that the actual performance of
the exchanger will differ from that required in some small but perhaps critical
respect. Use the Update Geometry facility under the Run option to create a
new input for running in Simulation or Checking Mode.
Note that even with simple exchangers, because Checking mode uses a
different calculation logic, the results will not be identical to the predictions of
the Design.
To decide whether a design is a good one, look at the following Results:
· Is the surface area margin adequate for all layers?
· Are the pressure drops of all streams within the specified limits?
· Do all layers have a similar heat load?
· Are the Nozzle and distributor losses reasonable - all below about 10% of
the available loss?
· Has all the available pressure drop been used?
· Do some streams have a very high Area Margin?
Within the context of its initial fin selection, the Design option will usually
obtain a reasonable optimization. You can try to obtain a better design by
pre-setting some of the geometry. Remember first to set the Geometry Input
switch under Options/Calculation Options so that the program takes your
input into account.
If the Distributor or nozzle losses are too high, you can specify a different
distributor configuration or nozzle size. End distributors can give lower losses
than side distributors.
If there is a lot of pressure drop available but unused, or if some streams
have a much higher area margin than needed, then the initial fin selection
could be unsuitable. You can either specify a different fin, for example, a
different fin height to change the number of layers for a given area, or just a
different type of fin, such as a perforated instead of serrated.

See also:
Improving a Design
Design Failures
 PlateFin: Improving a Design
Remember that PlateFin is only intended to provide a ‘First shot’ design
option. It does however provide facilities for exploring the effect of refining
design choices. In some cases, an experienced designer might make better
choices than the program. Improvements might be more significant for more
complex exchangers.
The first requirement for producing a more realistic design is to have access
to a databank of fin geometry and performance data for real fins that are
produced by an exchanger. If you did not use real fins in the initial run, select
the real fins that are closest to those suggested by PlateFin, specify these in
the input for both main fins and distributor fins, and re-run the Design.
PlateFin makes an initial selection of a main fin type for each stream and does
not revise this selection after doing a Design. An experienced designer might
be able to specify a better selection of fin for each stream. There is also a
facility for specifying different fins for different parts of the heat duty. For
example, you could specify a perforated fin for boiling and serrated fin for
subsequent superheating.
PlateFin does not identify a layer pattern, or worry too much about the ratio
of the number of hot and cold layers, other than requiring that the numbers
do not differ by a factor of more than two. An experienced designer can add
or remove a few layers to get the hot/cold ratio closer to 2 (or 0.5) or 1 which
can make it easier to define a good layer pattern. The exchanger width may
vary slightly, but the overall size of exchanger may be very little affected.
You can also improve the hot/cold ratio by reducing the fin height for one
stream. For example, if PlateFin suggests a design with a hot/cold ratio of 2.0
or 0.5 but the available pressure loss in some streams is far from being used
up, you might need to reduce the fin height in these streams.
Improvements might be possible to the header and nozzle location suggested.
Look also at the pressure losses in nozzles and distributors. You can specify
the distributor types and whether they are on the left or right. You might
chose to do this for some streams only and let the program re-position the
others. Re-run the Design and check that you have not made header or
nozzle losses worse.

See also:
Assessing a Design
Design Failures
 PlateFin: Design Failures
There are two types of design failure:
· You get a message that the design calculation has failed to find a design
consistent with size and pressure drop constraints, or
· The design is reported as being OK, but the exchanger diagram reveals
inconsistencies, such as an unphysical clash of headers for two streams.
If you get a Design failure message:
· First check that you have not specified impossible or inconsistent
geometry data. If a design needs ten exchangers in parallel, but you have
specified that there is only one, no design could be found. Similar
considerations apply if you have specified the number of layers for all or most
streams.
· Check that you have not specified an implausibly tight temperature
approach. Look at the hot and cold stream temperature profiles, where
temperature differences along the exchanger are recorded. Similarly, check
that the pressure drops you have specified are not implausibly small. Try re-
running the case with larger pressure drops, to identify whether any
particular stream is a problem.
If you do not get a design failure message but there are inconsistencies
evident in the diagram, for example in side header locations, then you may be
able to avoid the problem by moving headers to the other side of the
exchanger. You can do this by explicitly specifying the distributor type and
side for certain streams. Alternatively, if inconsistencies are small when you
crate a Simulation or Checking case from a Design, you can revise the input
to eliminate the discrepancy at that stage.

See also:
Assessing a Design
Improving a Design
 PlateFin: MUSE and PlateFin
The new Aspen Plate Fin Exchanger program (PlateFin) is based on (and will
eventually replace) the Aspen MUSE program. The two fundamental reasons
for the development of PlateFin were:
· To provide a common User Interface for all programs in the Aspen EDR
(Exchanger Design and Rating) series, and to make all the links and other
facilities available for calculations on plate-fin exchangers
· To provide a new calculation structure, removing limitations inherent in
the MUSE methods and providing a basis for a more extensive range of
calculations in future
Two parts of the MUSE code base have been used directly in PlateFin, so the
methods in these areas are essentially identical. These are
· Calculations of heat transfer coefficients and pressure gradients,
including all the technology from the HTFS research program. This provides
unique expertise on plate-fin exchangers, based on a program of
experimental measurements, and method and correlation development dating
back well over 30 years.
· The Design logic, permitting a "first shot" design to be established based
only on process and properties data for the streams and providing facilities for
the experienced designer to specify any aspect of the exchanger geometry,
leaving the program to optimize any unset values.
The maximum number of streams (20), fins, fin data points, properties data
points, and layers are all the same in PlateFin and MUSE, although it might be
increased in future releases.
The Aspen MUSE calculation has four calculation modes, sometimes referred
to by the names of four separate, earlier programs, which were incorporated
into Aspen MUSE. These are
· Stream-by-stream (common-wall-temperature) simulations [MUSE]
· Layer-by-layer simulations [MULE]
· Cross-flow exchanger simulations [MUSC]
· Design calculations [PFIN]

In PlateFin, there are four calculation options, and four geometry options.
· Calculation options
– Stream-by-stream (common-wall-temperature) simulations
– Layer-by-layer simulations
 – Stream-by-stream checking
– Design calculations
· Geometry options
– Standard axial flow exchangers
– Simple crossflow exchangers
– Multi-pass crossflow exchangers
– Plate-fin kettle reboilers
The last three geometry options are new to V7.2 and are available with
stream-by-stream simulations.
The solution procedure in PlateFin has been entirely re-written, so that the
same method can be used for all Simulation calculations and also for the new
Checking option. The new procedure is based on that previously used for
MULE, but re-written as a generic procedure for any exchanger type. It is
already in use in the Aspen Shell and Tube Exchanger program.
The program input for PlateFin is in many respects very similar to MUSE,
though the layout in the User Interface has been simplified. The file format is
different, but MUSE files can be imported into PlateFin. The major difference
is that in PlateFin, the exchanger geometry is specified based on the layout of
the layer types from which an exchanger is constructed. This gives much
more flexibility than the stream-based geometry input in MUSE.
The output of PlateFin incorporates all the major features of MUSE output, as
well as a significant amount of additional information. Improved grouping
should make outputs of various types easier to find, while redundancies in the
MUSE output have been removed. Unlike MUSE, the same output is produced
in all calculation modes.
The following important features, not mentioned above, are in both MUSE and
PlateFin:
· Thermosiphon reboilers
· Option for fin data from a user-databank
· Full range of distributor types
· Combining or dividing redistribution
· Prediction of flow maldistribution risk across layers
· Properties from COMThermo
· Import of properties and process data from HYSYS
· Longitudinal conduction
· Specification of layer-by-layer flow maldistribution
Some inputs associated with these forthcoming features are visible, but
grayed out and inaccessible.

The following new features are in PlateFin, but not MUSE:

· Checking calculations
· Full re-calculation of heat transfer coefficients and pressures at every
point at every iteration (no pre-calculated arrays)
· Heat transfer calculations in distributors
· Hardway fin
· Distributor pressure drops on a per layer, not aggregate, basis
· Full pipework specification for thermosiphons
· Thermosiphon calculation to determine inlet resistance needed
· Multiple main fins per stream in Design
· Enhanced user control of iteration convergence
· Full access to Aspen properties
· Active input checking, with display of defaults in the GUI
· Recap table comparing results of a sequence of runs
· Linking of any input or output variables to Excel
· Customization of units, for every input and output variable
 Headings Sheet
Use this sheet to specify Headings, which appear at the top of the TEMA
specification sheet, Input Summary results, and the Title block of the
drawings. Headings are 1 to 5 lines of up to 75 characters per line. Note that
only the first 40 characters of each line appear on the drawings.
To create global headings for use by any Aspen EDR program, click Tools |
Program Settings, display the Headings/Drawings tab, and enter the
heading information.
 Ensea Application Options Sheet
Use this sheet to specify:
Application type
TEMA class
If you want the heat exchanger to be built according to TEMA standards,
select the appropriate TEMA class: B (default), C, or R. If TEMA is not a design
requirement, specify Code only, and the program will use only the design
code to determine the mechanical design.
For the tube layout you can have the program generate a new layout every
time the program runs (default), or you can run the program to generate a
layout and use this existing layout for all subsequent runs.
After you have run the program and generated tube layout drawing, you can
modify the tube layout interactively.
 Application Type
If you select design a tube layout for specified vessel diameter, the
program holds the specified vessel diameter and determines the number of
tube holes that will fit based on other tube layout information provided.
Selecting design a tube layout for specified number of tubes allows you
specify the number of tubes and the program determines what shell size is
required for that number of tubes based on tube and baffle information you
have provided.
Selecting specify the tube layout allows you to specify the number of tube
holes in each row, the location of each row, the tie rods, baffle cuts, and pass
partitions. This option is primarily aimed at preparing a drawing of an existing
or known tubesheet layout.
 Drawing
After you specify the exchanger geometry, run the program to generate the
tube layout drawing. You can modify the tube layout interactively.
Tubes
To remove a tube, click the tube to highlight it (in red) and then select the
red X on the menu.
To identify a tube as a plugged tube or a dummy tube, click the tube to
highlight it (in red) and then select the plugged tube icon or dummy tube icon
on the menu.
Tie Rods
To remove a tie rod, click the tie rod to highlight it (in red) and then select
the red X on the menu.
To add a tie rod, select the add a tie rod icon on the menu and then specify
the location of the tie rod.
Sealing Strips
To remove a sealing strip, click on the sealing strip to highlight it (in red) and
then select the red X on the menu.
To add a sealing strip, select the add a sealing strip icon on the menu and
then specify the location of the sealing strip.
 Exchanger Type Sheet
Use this sheet to specify:
Front head type
The front head type does not affect the tubesheet layout. It is included in the
input for completeness of the TEMA designation (e.g., BEM). The default is B.
Shell type
The shell type does not affect the tubesheet layout, except for those cases
where there is a longitudinal baffle (types F, G, and H). For these cases the
program avoids a solution where the longitudinal baffle would pass through
the middle of a pass, for example, a 6 pass quadrant layout. The default is E.
Rear head type
The rear head type significantly affects the tubesheet layout, because it
determines the outer tube limits (OTL) and therefore the number of tubes.
The L, M (default), and U type (default for K type shells) rear heads have the
same OTL, which the program calculates accurately.
The P, S, T, and W (and to some extent the N) rear head types have an OTL
which is very dependent on the mechanical design. The program estimates
the clearance requirements for these other heads, but the OTL may not be
exact. Use Aspen Shell&TubeMech to determine the exact outer tube limit for
floating head heat exchangers.
 Dimensions Sheet
Use this sheet to specify:
Front head inside diameter
You should specify the front head inside diameter whenever it is less than the
shell inside diameter. If you leave it zero, the program uses the shell ID to
determine the outer tube limit.
Shell inside diameter
You should always specify the shell ID except when you want the program to
determine the smallest shell size that will contain the given number of tubes.
The program uses the shell ID to calculate the outer tube limit (if not
specified) and the baffle OD, to locate the tie rods and the baffle cut, as well
as a reference for limiting the layout along the horizontal and vertical axis.
Shell outside diameter
The program determines the smallest shell outer diameter based on the
specified inner diameter. For a shell ID within 24 inches, the program defaults
to a 0.375 inch tube wall thickness. Otherwise, the program determines shell
OD based on 0.5 inch shell wall thickness.
Outer tube limit diameter
This the diameter of the circle beyond which no portion of a tube will be
placed. The program allows the outer edge of a tube to be on the outer tube
limit (OTL).
If you specify zero, the program calculates the OTL based on the front and
rear head types and the front head ID and the shell ID.
The program calculated OTL should be exact for fixed tubesheet exchangers
with rear head types L and M and U-tube exchangers (rear head type U). It
may not be exact for exchangers with N type heads, floating head exchangers
(rear head types P, S, or T), or floating tubesheet exchangers (rear head type
W), since the program makes assumptions on the gasket width, bolt size, and
barrel thickness. For an exact OTL, you should use Aspen Shell&TubeMech.
 Tubes Sheet
Use this sheet to specify:
Number of tube holes
If you have established an exact number of tubes, specify the number of
tubes. If you want the program to maximize the number of tubes for a given
shell size, you should leave this input field blank.
Tube outside diameter
You can specify any size for the tube outside diameter.
Tube pitch
This is the distance from tube center to tube center within the tube pattern.
The default is per TEMA standards for specified tube diameter
Tube pattern
The tube pattern is the layout of the tubes in relation to the direction of the
shell side crossflow, which is normal to the baffle cut edge. The one exception
to this is pool boiling in a kettle type reboiler where the tube supports are
sometimes baffles with a vertical cut.
 Number of tube holes
If you want the program to maximize the number of tubes for a given shell
size, you should leave this input field blank.
If you have already established an exact number of tubes, specify the number
of tubes. The program attempts to find a reasonable layout with that tube
count. If it cannot find a layout with that many tubes, it shows the layout with
the maximum tubes it could find. If the specified tube count is below the
program's normal solution, the program removes tubes until it reaches the
desired count.
If you want to find the smallest shell ID to contain a given number of tubes,
enter the desired tube count, and enter zeros for the shell ID and outer tube
limits. The program will search through several shell sizes until it finds the
smallest size, rounded to the nearest 0.25 inch or the nearest 5 mm,
depending upon the system of measure. For U-tubes, you should specify the
number of tube holes (two times the number of U's).
Default: program calculated
 Ensea Baffles Sheet
Use this sheet to specify:
Type of baffles
The default is single segmental ( full support X type shell). The program also
covers full supports and the two types of grid baffles: rod baffles and strip
baffles. Rod baffles are limited to a tube pattern of square or rotated square.
Strip baffles are for triangular tube patterns.
If you specify no tubes in the window (NTIW), the program will not place any
tube beyond the baffle cut, minus an edge distance of 0.125 in or 3.2 mm.
Baffle cut (% of diameter)
For single segmental baffles, specify the percentage of the baffle window
height compared to the shell ID. For double and triple segmental baffles,
specify the percentage of the innermost baffle window height compared to the
shell ID.
Baffle orientation
The baffle orientation - horizontal (default), vertical, or rotated 45 degrees
- affects the appearance of the tube pattern and the location of the tie rods.
Rotated orientation may be used only with a square or rotated square tube
pattern.
 Baffle Cut
For single segmental baffles, specify the percentage of the baffle window
height compared to the shell ID.
For double and triple segmental baffles, specify the percentage of the
innermost baffle window height compared to the shell ID.
Baffle Type Baffle Cut

Between 15 and
Single segmental
45%

Between 30 and
Double segmental
40%

Between 15 and
Triple segmental
20%

Full support Zero

Grid Zero

Note: The values are not limited to those listed, which are provided as a
convenience.
For more information on double and triple segmental baffle cuts, see the
Appendix.
 Tie Rods/Spacers Sheet
The program optimizes the location of the tie rods to maximize the number of
tube holes in the layout. Use this sheet to specify the number of tie rods,
which can be any even number between 4 and 12. The default is per TEMA
standards.
You can specify the tie rod and spacer outside diameters or allow the
program to use default sizes.
Program Defaults
Tie Rod Spacer Tie Rod Space
(mm) (mm) (in) (in)

6.5 12.7 0.25 0.5

9.5 15.9 0.375 0.625

12.7 19.1 0.5 0.75

15.9 25.4 0.625 1.0

 Tube Layout Sheet
Use this sheet to specify:
Pass layout type
Number of tube passes
You can specify any number of passes from 1 to 16.
Maximum % deviation in tubes per pass
For thermal performance and pressure drop reasons, it is normally desirable
to reasonably balance the number of tubes per pass in multi-pass layouts.
This input indicates the maximum percentage of deviation from the median
number of tubes per pass (average between the lowest and highest number of
tubes in a pass). The default is 5% maximum deviation. Values are not
limited to those listed.
To force the same number of tubes in each pass, specify 0.001.
Pass partition lane width
The clearance lane is the edge to edge distance between the tube rows on
each side of a pass partition. If the tubes are welded into the tubesheet, a
clearance of at least 0.75 in or 19.1 mm should be used.
Defaults are 15.9 mm or 0.625 in for TEMA B & C exchangers; 19.1 mm or
0.75 in for TEMA R exchangers
Design symmetrical tube layout
 Pass Layout Type
For 1, 2, or 3 pass layouts, the value of this input field is not pertinent. For
pass layouts of 4 or more tube passes, the value specified here determines
how the tube side inlet and outlet nozzles will enter the heads and the
locations of the pass partitions.
The difference between ribbon type and mixed type layouts is in how the
inner passes (the passes between the first and last passes) are constructed. In
the ribbon layout, each pass stretches from one side of the shell to the other,
whereas the mixed layout has a vertical pass partition plate dividing the inner
passes. The figure shows a 4-pass layout in each of the layout types.

Mixed and ribbon type layouts have the advantage of easier nozzle
installation, especially with relatively large nozzles. Ribbon type is also
preferable when there is a large pass to pass temperature change, since
ribbon type minimizes the local temperature stresses in the tubesheet.
Quadrant type layouts have the advantage of normally (but not always)
yielding a greater number of tubes.
U-tube layouts of 4 or more passes are restricted to the quadrant type.
Default: program will optimize to the greatest number of tubes.
 Design symmetrical tube layout
The program will always make the left half symmetrical to the right half of the
layout, but the top half can be nonsymmetrical to the bottom half. If different
values are specified on the Limits sheet for "tube limit along vertical
centerline" measured in from top and from bottom, the layout will always be
nonsymmetrical. In some cases of nonsymmetrical layouts, you may still want
to force a pass partition to be on the horizontal centerline or a tube row to be
on the centerline. To do this, select the design symmetrical tube layout
option.
This parameter is also valuable in the case of a single pass layout where the
number of tubes and the shell ID are specified as input to the program. If a
greater number of tubes can fit in the shell, the program will eliminate tubes.
For a non-symmetrical layout, the program will eliminate tubes only at the
top of the bundle. For a symmetrical layout, the program will eliminate the
appropriate tubes from both the top and the bottom of the layout.
Default: non-symmetrical
 Limits Sheet
Use this sheet to specify:
Open space between shell ID and tube bundle
You can specify the clearance from the shell inside diameter to the tube
bundle at the top (S1), bottom (S2), and sides (S3). By default the
program minimizes clearance to maximize tube count.
Distance from tube center - to vertical (D1), horizontal (D2)
centerlines
You can use either or both of these input fields to force the program to start
the layout in a specific way.
Location of center tube in 1st row
Use this input field to force the program to start the layout in a specific way.
The location of the first tube in the first row from the bottom is pertinent for
triangular, rotated triangular, and rotated square layouts, where the rows are
staggered.
If you select off center line, the program locates the tubes near the vertical,
off of the vertical centerline in the first row from the bottom. If you select on
center line, the program locates a tube on the vertical centerline for the first
row from the bottom.
Clearance - shell ID to baffle OD
This determines the outer limits for spotting tie rods. The program will place
the OD of the spacer within 0.125 in or 3.2 mm of the baffle edge. The default
is per TEMA standards.
Minimum u-bend diameter
This determines the minimum tube center-to-center distance of any U-tube
bundle.
Straight length for u-tubes
If the layout is for a U-tube bundle, the program prints out a U-bend schedule
showing the quantity for each different length U-tube. The program assumes
that the bends for all the tubes start at the same distance from the tubesheet
and are in parallel planes.
 Distance from tube center to vertical and
horizontal centerlines
You can use either or both of these entries when you want to force the
program to start the layout in a specific way.
To force tubes to be on either or both of the centerlines, specify a value of
zero for the respective distance. If field is left blank, the program will
optimize.
For nonsymmetrical layouts, the program will observe the specified distance
from the vertical centerline, but it ignores a specified distance from the
horizontal centerline. However, the distance from the horizontal centerline
can be controlled by entering a value for the "Tube Limit from Top of Shell ID
along Vertical centerline" equal to the top edge of the last tube row.
Default: program optimized
 Minimum U-Bend Diameter
This determines the minimum tube center-to-center distance of any U-tube
bundle.
For 2-pass. U-tube layouts, it determines the distance from the pass partition
to the first row of tubes on each side of the pass partition.
For layouts of 4 or more passes, it determines the distance on each side of
the vertical pass partition.
The choice of a minimum bend diameter must take into account what the tube
material is, what the wall thickness is, how much thinning in the bend is
permissible, and what bending dies and procedures are to be used.
Default: three times the tube OD
 Nozzle/Impingement Plate Sheet
Use this sheet to specify the shell side inlet nozzle outside diameter and
orientation, and impingement protection parameters.
Shell side inlet nozzle
The program uses the shell side inlet nozzle outside diameter to determine
the position of the impingement plate. This dimension is not required if you
specify the impingement plate diameter.
The program uses the shell inlet nozzle orientation to determine the
orientation of the impingement plate. The orientation is required if you
specify the impingement plate.
If you have done the thermal design for this heat exchanger, these input
fields display the results determined from the thermal design program.
Impingement protection
The purpose of impingement protection is to protect the tubes directly under
the inlet nozzle by deflecting the bullet shaped flow of high velocity fluids or
the force of entrained droplets.
If you have done the thermal design for this heat exchanger, the
impingement protection type displayed is from thermal design program.
You can also specify these impingement plate dimensions:
Diameter
The diameter determines the position and the dimension of the impingement
plate This input is not required if you have already specified the shell inlet
nozzle OD (default).
Length (parallel to tube axis)
Width (normal to tube axis)
Use the length and width to specify a rectangular impingement plate size. The
default length and width (square plate) is the shell inlet nozzle OD.
Thickness
This is required if you specify an impingement field. You can specify any
thickness for the impingement plate. The default is 3 mm or 0.125 in.
Distance in from shell ID
You can specify the distance from the shell inside diameter to the
impingement plate. The default is top row of tubes.
Clearance to tube edge
You can specify the distance from the impingement plate to the first row of
tubes.
Perforation area %
If you are using a perforated type impingement plate, you can specify the
percent of area that the plate is perforated.
 Tube Row Details
If you are specifying the details from an existing tube layout to generate a
tube layout drawing, use this sheet to provide the row number, number of
holes, and location of tube row for each row in the tube layout. You can also
specify the tie rod, pass partition, and baffle cut locations.
 Ensea Results
The output from ENSEA is divided into six sections:
Input Data
Warnings and Messages
Tubesheet Layout Summary
Tube Row Details
U-bend Details
U-bend Totals
You can display and/or print any or all parts of this output. The format of the
output is consistent between display and printed output, typically with two or
three display screens equal to one printed page. Most printed pages will also
have a heading with the program name, version, time, date, and filename.
 Input Data
You can display the input data in a more condensed format than used in the
input. It is recommended that you request the input data as part of your
printed output so that it is easy to reconstruct the input which led to the
design.
 Warnings & Messages
Aspen EDR provides an extensive system of warnings and messages to help
the designer of heat exchanger design. Messages are divided into five types.
There are several hundred messages built into the program. Those messages
requiring further explanation are described here.
Warning Messages: These are conditions, which may be problems, however
the program will continue.
Error Messages: Conditions which do not allow the program to continue.
Limit Messages: Conditions which go beyond the scope of the program.
Notes: Special conditions which you should be aware of.
Suggestions: Recommendations on how to improve the design.
 Summary
The Summary section provides general information about the tubes, the tube
layout design parameters, and clearances.
Outer tube circle
The outer tube circle is often slightly different than the outer tube limit.
Whereas the o.t.l. is the limit beyond which no tube can extend, the outer
tube circle is the actual diameter determined by the outer edge of the
outermost tube, measured radially.
Equivalent tube perimeter
This is the "equivalent diameter of the tube center limit perimeter" as defined
in TEMA 7.133 Tubesheet Formula - Shear. It is equal to four times the area
enclosed by the tube perimeter divided by the tube perimeter.
Maximum deviation from median
This is the maximum deviation from the median number of tubes per pass,
shown "Before Balancing" and "After Balancing." "Before Balancing" is before
the program removes tubes to satisfy the specified (or defaulted) input for
Maximum Deviation. "After Balancing" is the recomputed deviation for the
tubesheet layout shown and should always be within the specified maximum.
 Tube Row Details
The Tube Row Detail section provides a per row tube count and row
location. Most of this output is self explanatory. The items needing some
additional explanation are:
Row number and number of holes
Row indicates the tube row number. Row number 1 is always at the bottom of
the layout. The number of holes is the total number of holes in that row.
Distance offset from centerlines
The first column is the distance from the vertical centerline (x-axis) to the
center of the first tube in that row, counting from the vertical centerline. If a
tube is on the vertical centerline, the value will be 0.0. The second column is
the distance from the horizontal centerline (y-axis) to the center of each tube
in the row. A positive value indicates the row is above the horizontal
centerline; a negative value indicates it is below. If a tube is on the horizontal
centerline, the value will be 0.0.
 Tube Layout Drawing
Once you have run the Ensea program and have tube layout results, you can
interactively make modifications to the tube layout.
After you complete your changes to the tube layout, you may want to select
the "Use existing layout" option located on the Application Options sheet.
See also:
Drawing
 Ensea Logic
The right half and left half of layout are always symmetrical for tube hole
placement. Top and bottom halves can be nonsymmetrical.
The program assumes that tube side nozzles are at the top and bottom of the
layout (offset from the vertical centerline for quadrant type layouts).
If the number of tubes is not given as input, the program will maximize the
number of tubes by trying several solutions, varying one or more of the
following:
Location of first tube row in relation to the vertical centerline
Location of pass partition plates
Pass layout type
If the number of tubes is given as input, the program will choose the layout
which requires the fewest tubes to be eliminated to arrive at the desired
number or the layout which has the least deviation in number of tubes per
pass.
If tubes are eliminated in order to balance the number of tubes per pass or to
match a given number of tubes, the program follows this procedure:
For the passes on the bottom or the top:
Tubes are eliminated starting from the end of the outermost row and moving
toward the vertical centerline in that row, until the number of tubes is met.
For inner passes:
Tubes are eliminated from each row, one tube per row, from the periphery of
the bundle until the number of tubes is met.
U-tube layouts of 4 or more passes are always quadrant type.
U-tubes are always bent in parallel planes.
Cleaning lanes are always maintained for square and rotated square patterns
for removable bundles in TEMA heat exchangers.
The baffle cut is cut through the center of a tube row except for baffles with
no tubes in the window.
Longitudinal baffles are assumed to be of the same thickness as pass partition
plates and match the location of a pass partition.
Sealing strips are assumed to not affect the placement of tubes.
Multi-segmental baffle cuts are chosen so that the total window areas per
baffle are approximately equal. Whenever possible there is at least one tube
row which is common to each baffle set. Reference the Appendix for more
information on baffle cuts.
Tie rods are located according to the following logic:
spacers are at least 0.125 inch or 3.2 mm from the nearest tube and from the
baffle edge.
Tie rods between the first and last tube rows are at the periphery of the
bundle on or between tube rows.
Preference is given to locations where tubes are not displaced.
Preference is given to locations evenly distributed around the bundle or close
to the baffle cut when appropriate.
The tubesheet layout is drawn to scale. The scale is chosen by the program.
The program draws all of the pitch lines within the o.t.l. It also draws the tube
holes for each tube along the perimeter of each pass.
 Ensea References
For a further understanding of subjects relating to ENSEA, see the following
publications:
Terminology, Construction Types, and Clearances
Standards of Tubular Exchanger Manufacturers Association, TEMA, Seventh
Edition, 1988
Pass Layout Types
Heat Exchangers: Design and Theory Sourcebook, Afgan and Schlunder,
pp.33-34 (section author, K.A. Gardner), McGraw-Hill, New York, 1974
Numerical Control
Programming for Numerical Control Machines, A.D. Roberts and R.C. Prentice,
McGraw-Hill, New York, 1968
Modern Machine Shop NC/CAM Guidebook, Gardner Publications, Rookfield,
Wisconsin
 TEMA Specification Sheet Descriptions
Use this sheet to specify Headings, which appear at the top of the TEMA
specification sheet, Input Summary results, and the Title block of the
drawings. Headings are 1 to 5 lines of up to 75 characters per line. Note that
only the first 40 characters of each line appear on the drawings.
To create global headings for use by any Aspen EDR program, click Tools |
Program Settings, display the Headings/Drawings tab, and enter the
heading information.
 Shell/Heads Sheet
Use this sheet to specify the shell and head types and exchanger position.
Front head type
The front head type should be selected based on the service needs for the
exchanger. A full access cover provided in the A, C, and N type heads may be
needed if the tube side of the exchanger must be cleaned frequently. Type B
(default) is generally the most economical type head.
Shell type
The shell type determines the shell side flow arrangement and the place of
the shell side nozzles. The default is type E (except K type shell side pool
boilers).
Rear head type
The rear head typeaffects the thermal design, because it determines the outer
tube limits and therefore the number of tubes and the required number of
tube passes. Type U is the default for kettle shells; for all others, M.
Exchanger position
Specify whether the exchanger is to be installed in the horizontal or vertical
position. The default is vertical for tube side thermosiphon; for all others,
horizontal.
 Shell type
The shell type determines the shell side flow arrangement and the place of
the shell side nozzles.
Type Description

Generally provides the best heat transfer but

also the highest shell side pressure drop. Used
E
for temperature cross applications where pure
counter current flow is needed.

This two pass shell can enhance shell side heat

F transfer and also maintain counter current flow
if needed for temperature cross applications.

Will enhance the shell side film coefficient for a

G
given exchanger size.

A good choice for low shell side operating

H pressure applications. Pressure drop can be
minimized. Used for shell side thermosiphons.

Used often for shell side condensers. With two

inlet vapor nozzles on top and the single
J
condensate nozzle on bottom, vibration
problems can be avoided.

K Used for kettle type shell side reboilers.

Good for low shell side pressure applications.

Units is provided with support plates which
provides pure cross flow through the bundle.
X
Multiple inlet and outlet nozzles or flow
distributors are recommended to assure full
distribution of the flow along the bundle.

This type is not currently part of the TEMA

standards. It is used for very low shell side
V pressure drops. It is especially well suited for
vacuum condensers. The vapor belt is an
enlarged shell over part of the bundle length.

Default: E type (except K type shell side pool boilers)

 Tubesheets/Expansion Joints Sheet
Use this sheet to specify:
Tubesheet type
The tubesheet type has a very significant effect on both the thermal design
and the cost.
Tube to tubesheet joint
The tube to tubesheet joint does not affect the thermal design, but it does
have a small effect on the mechanical design and sometimes a significant
effect on the cost.
Expansion joint
The specification of an expansion joint does not affect the thermal design
calculations, but does have a significant effect on the cost. This item only
applies to fixed tubesheet heat exchangers; it is ignored for all other types.
The default is program, based on the estimated differential expansion.
Note that the calculations required to determine the need for an expansion
joint are quite complex and are beyond the scope of Shell&Tube. These
calculations are part of the Shell&TubeMech program. However, Shell&Tube
will estimate the differential expansion between the tubes and the shell and
make a simple determination on the need for an expansion joint if you use
the program default.
 Tubesheet type
The tubesheet type has a very significant effect on both the thermal design
and the cost. The default is normal single tubesheet(s).
Double tubesheets are used when it is extremely important to avoid any
leakage between the shell and tube side fluids. Double tubesheets are most
often used with fixed tubesheet exchangers, although they can also be used
with U#tubes and outside packed floating heads.
Double tubesheets shorten the length of the tube which is in contact with the
shell side fluid and therefore reduce the effective surface area. They also
affect the location of the shell side nozzles and the possible baffle spacings.
The gap type double tubesheet has a space, usually about 150 mm (6 in.),
between the inner (shell side) and outer (tube side) tubesheets. The integral
type double tubesheet is made by machining out a honeycomb pattern inside
a single thick piece of plate so that any leaking fluid can flow down through
the inside of the tubesheet to a drain. This type is rare, since it requires
special fabrication tools and experience.
See also:
Tubesheets/Expansion Joints Sheet
 Tube to tubesheet joint
The tube to tubesheet joint does not affect the thermal design, but it does
have a small effect on the mechanical design and sometimes a significant
effect on the cost.
The most common type of tube to tubesheet joint is expanded only with 2
grooves. Although TEMA Class C allows expanded joints without grooves, most
fabricators will groove the tube holes whenever the tubes are not welded to
the tubesheet.
For more rigorous service, the tube to tubesheet joint should be welded. The
most common welded joints are expanded and seal welded with 2 grooves and
expanded and strength welded with 2 grooves.
For normal service the default is expanded only with 2 grooves; for lethal
service the default is expanded and strength welded with 2 grooves.
See also:
Tubesheets/Expansion Joints Sheet
 Shell Sheet
Use this sheet to specify these exchanger data details:
Gross surface area
If you do not know the exact configuration of the exchanger, you can specify
the gross surface area, and the program will determine a reasonable
geometry based on the program defaults. If you do not specify the gross
surface area, then you must provide values for the number of tubes, tube
outside diameter, and tube length.
Shell outside, inside diameter
If you do not specify the surface area, you must specify either the actual shell
outside or inside diameter. If you specify the shell OD, we recommend leaving
the ID blank.
For pipe size exchangers, we recommend specifying the shell OD rather than
ID, since the program references standard pipe schedules. For exchangers
made of rolled and welded plate materials, specify either the shell OD or ID.
For kettles, the shell diameter is for the small cylinder near the front
tubesheet, not the large cylinder.
Baffle spacing center-center
Specify the center to center spacing of the baffles in the bundle.
Baffle spacing at inlet
Specify the inlet baffle spacing at the entrance to the bundle. For G, H, J, and
X shell types, this is the spacing from the center of the nozzle to the next
baffle. These types should have a full support under the nozzle. If left blank,
the program calculates the space based on the center to center spacing and
the outlet spacing. If the outlet spacing is not provided, the program
determines the remaining tube length not used by the center to center
spacing and provides equal inlet and outlet spacings.
Number of baffles
The number of baffles is optional input. If you do not know the number of
baffles, inlet, or outlet spacing, you can approximate the number of baffles by
dividing the tube length by the baffle spacing and subtracting 1. However, if
you do not know the number of baffles, it is best to let the program calculate
it, because it will also consider the tubesheet thickness and nozzle sizes. The
number of baffles for G, H, and J type shells should include the baffle or full
support under the nozzle.
Tube length
Specify the tube length. The length should include the length of tubes in the
tubesheets. For U-tube exchangers, specify the straight length to the U-bend
tangent point.
Number of tubes
Specify the number of tube holes in the tubesheet. This is the number of
straight tubes or the number of straight lengths for a U-tube. If you specify
the number, the program checks to make sure that number of tubes can fit
into the shell. If you do not specify it, the program calculates number of tubes
using the tubesheet layout subroutine.
Tube passes
Provide the number of tube passes in the exchanger.
Kettle outside diameter
Specify the actual kettle outside diameter. For pipe size exchangers, we
recommend specifying a kettle OD rather than an ID, since the program
references standard pipe schedules. For exchangers made of rolled and
welded plate materials, specify either the kettle OD or ID.
 Tubes Sheet
Use this sheet to specify these exchanger data details:
Tube type
The program covers plain tubes (default) and external integral
circumferentially finned tubes.
Fin density
If you specify fin tubes as the tube type, then you must specify the desired fin
density (i.e., the number of fins per inch/per meter). Since the possible fin
densities are very dependent on the tube material, you should be sure that
the desired fin density is commercially available.
Tube outside diameter
You can specify any size for the tube outside diameter. Correlations have
been developed based on tube sizes from 10 to 50 mm (0.375 to 2.0 inch).
For integral finned tubes, this is the outer diameter of the fins.
Tube wall thickness
The tube wall thickness should based on considerations of corrosion, pressure,
and company standards. Tube wall thickness can be specified or calculated by
the program.
Tube pitch
The tube pitch is the center-to-center distance between two adjacent tubes
Tube pattern
The tube pattern is the layout of the tubes in relation to the direction of the
shell side crossflow, which is normal to the baffle cut edge. The one exception
to this is pool boiling in a kettle type reboiler where the tube supports are
sometimes baffles with a vertical cut.
 Tube type
The program covers plain tubes (default) and external integral
circumferentially finned tubes.
Externally finned tubes become advantageous when the shell side film
coefficient is much less than the tube side film coefficient. However there are
some applications where finned tubes are not recommended. They are not
usually recommended for cases where there is high fouling on the shell side
or for condensation where there is a high liquid surface tension.
The dimensional standards for Wolverine and High Performance finned tubes
are built into the program. These standard finned tubes are available in tube
diameters of 12.7, 15.9, 19.1, and 25.4 mm or 0.5, 0.625, 0.75, and 1.0
inch.
See also:
Enhanced Surfaces Standard Sizes for a list of the available standard tube
sizes.
 Fin density
If you specify fin tubes as the tube type, then you must specify the desired fin
density (i.e., the number of fins per inch or per meter depending on the
system of measure). Since the possible fin densities are very dependent on
the tube material, you should be sure that the desired fin density is
commercially available.
The dimensional standards for finned tubes made by Wolverine, and High
Performance Tube are built into the program. If you choose one of these, the
program will automatically supply the corresponding fin height, fin thickness,
and ratio of tube outside to inside surface area.
The standard fin densities for various materials are:
Material Fin Density

Carbon Steel 19

Stainless Steel 16, 28

Copper 19, 26

Copper-Nickel
16, 19, 26
90/10

Copper-Nickel
19, 26
70/30

Nickel Carbon Alloy

19
201

Nickel Alloy 400

28
(Monel)

Nickel Alloy 600

28
(Inconel)

Nickel Alloy 800 28

Hastelloy 0

Titanium 30

Admiralty 19, 26

Aluminum-Brass
9
Alloy 687
 Tube outside diameter
You can specify any size for the tube outside diameter. However, the
correlations have been developed based on tube sizes from 10 to 50 mm
(0.375 to 2.0 inch). The most common sizes in the U.S. are 0.625, 0.75, and
1.0 inch. In many other countries, the most common sizes are 16, 20, and 25
mm.
If you do not know what tube diameter to use, start with a 20 mm diameter
(ISO standards) or a 0.75 inch diameter (American standards). This size is
readily available in nearly all tube materials. The primary exception is
graphite, which is made in 32, 37, and 50 mm, or 1.25, 1.5, and 2 inch
outside diameters.
For integral low fin tubes, the tube outside diameter is the outside diameter
of the fin.
Default: 19.05 mm or 0.75 inch
 Tube wall thickness
The tube wall thickness should be based on considerations of corrosion,
pressure, and company standards. If you work with ANSI standards, the
thicknesses follow the BWG standards.
The program defaults are a function of material per TEMA recommendations
and a function of pressure. Shell&Tube checks the specified tube wall
thickness for internal pressure and issues a warning if it is inadequate. For
low fin tubes, the tube wall thickness specified will be maintained below the
fins.
0.065 in. or 1.6
mm
carbon steel
0.028 in. or 0.7
titanium
mm
Defaults: graphite
0.180 in. or 5
other mm
materials
0.049 in. or 1.2
mm

Note: The values are not limited to those listed, which are provided as a
convenience.
 Tube pitch
The tube pitch is the center-to-center distance between two adjacent tubes.
Generally, the tube pitch should be approximately 1.25 times the tube OD. It
some cases, it may be desirable to increase the tube pitch in order to better
satisfy the shell side allowable pressure drop. Increasing the tube pitch
beyond 1.5 times the tube OD is not recommended.
Minimum tube pitches are suggested by TEMA as a function of tube OD, tube
pattern, and TEMA class. The program defaults to the TEMA minimum tube
pitch, if you are designing to TEMA standards.
The DIN standards also cover tube pitch. The DIN tube pitches are a function
of tube OD, tube pattern, and tube to tubesheet joint. The program defaults
to the DIN standard if you are designing to DIN standards.
 Tube Pattern
The tube pattern is the layout of the tubes in relation to the direction of the
shell side crossflow, which is normal to the baffle cut edge. The one exception
to this is pool boiling in a kettle type reboiler, where the tube supports are
sometimes baffles with a vertical cut.
Use triangular when you want to maximize the shell side film coefficient and
maximize the number of tubes, and shell side cleaning is not a major concern.
If you must be able to mechanically clean the shell side of the bundle, then
choose square or rotated square.
Square is recommended for pool boilers to provide escape lanes for the vapor
generated.
Rotated square will give the higher film coefficient and higher pressure
drop, but it will usually have fewer tubes than a square layout.
Rotated triangular is rarely the optimum, because it has a comparatively
poor conversion of pressure drop to heat transfer.
Defaults: triangular for fixed tubesheet exchangers; square for pool boilers
 Baffle Type
Baffle types can be divided up into two general categories:
Segmental baffles are pieces of plate with holes for the tubes and a segment
that has been cut away for a baffle window. Single, double, triple, and no
tubes in window are examples of segmental baffles.
Grid baffles are made from rods or strips of metal, which are assembled to
provide a grid of openings through which the tubes can pass.
Segmental baffles are the most common type of baffle, with the single
segmental baffle being the type used in a majority of shell and tube heat
exchangers. The single segmental baffle gives the highest shell film coefficient
but also the highest pressure drop. A double segmental baffle at the same
baffle spacing will reduce the pressure drop dramatically (usually somewhere
between 50% - 75%) but at the cost of a lower film coefficient. The baffles
should have at least one row of overlap and therefore become practical for a
20 mm or 0.75 in. tube in shell diameters of 305 mm (12 in.) or greater for
double segmental and 610 (24 in.) or greater for triple segmental baffles.
(Note: the Aspen EDR triple segmental baffle is different than the TEMA triple
segmental baffle.)
Full Supports are used in K and X type shells where baffling is not necessary
to direct the shell side flow.
No Tubes In Window is a layout using a single segmental baffle with tubes
removed in the baffle windows. This type is used to avoid tube vibration and
may be further enhanced with intermediate supports to shorten the
unsupported tube span. The standard abbreviation for no tubes in the window
is NTIW.
The program covers two types of grid baffles: rod baffles and strip baffles.
Both are used in cases where the allowable pressure drop is low and the tube
support is important to avoid tube vibration.
Rod Baffle design is based on the construction and correlations developed by
Phillips Petroleum. Rod baffles are limited to a square tube pattern. The rods
are usually about 6 mm (0.25 in.) in diameter. The rods are placed between
every other tube row and welded to a circular ring. There are four repeating
sets where each baffle is rotated 90 degrees from the previous baffle.
Strip Baffles are normally used with a triangular tube pattern. The strips are
usually about 25 mm (1 in.) wide and 3 mm (0.125 in.) thick. The strips are
placed between every tube row. Intersecting strips can be notched to fit
together or stacked and tack welded. The strips are welded to a circular ring.
Strip baffles are also sometimes referred to as nest baffles.
Default: single segmental except X shells; full support for X shell
 Baffle cut (% of diameter)
The baffle cut applies to segmental baffles and specifies the size of the
baffle window as a percent of the shell inside diameter.
For single segmental baffles, the program allows a cut of 15% to 45%.
Greater than 45% is not practical because it does not provide for enough
overlap of the baffles. Less than 15% is not practical, because it results in a
high pressure drop through the baffle window with relatively little gain in heat
transfer (poor pressure drop to heat transfer conversion). Generally, where
baffling the flow is necessary, the best baffle cut is around 25%.
For double and triple segmental baffles, the baffle cut pertains to the
most central baffle window. The program automatically sizes the other
windows for an equivalent flow area.
45% for simple condensation
single
Defaults: and pool boiling; 25% for all
segmental
others

double
28% (28/23)
segmental

triple
14% (14/15/14)
segmental

See also:
Baffle Cuts
 Baffle cut orientation
The baffle orientation applies to the direction of the baffle cut with segmental
baffles. It is very dependent on the shell side application.
For horizontal, shell side condensation applications, the cut should be
oriented vertically. This will facilitate condensate drainage. For all other
applications, the cut orientation is not as critical. The program defaults to
vertical cut for horizontal condensers and horizontal cut for all other
applications.
For a single phase fluid in a horizontal shell, the preferable baffle orientation
of single segmental baffles is horizontal, although vertical and rotated are
usually also acceptable. The choice will not affect the performance, but it will
affect the number of tubes in a multipass heat exchanger. The horizontal cut
has the advantage of limiting stratification of multicomponent mixtures, which
might separate at low velocities.
The rotated cut is rarely used. Its only advantage is for a removable bundle
with multiple tube passes and rotated square layout. In this case the number
of tubes can be increased by using a rotated cut, since the pass partition lane
can be smaller and still maintain the cleaning paths all the way across the
bundle. (From the tubesheet, the layout appears square instead of rotated
square.)
For horizontal shell side condensers, the orientation should always be
vertical, so that the condensate can freely flow at the bottom of the heat
exchanger. These baffles are frequently notched at the bottom to improve
drainage. For shell side pool boiling, the cut (if using a segmental baffle)
should be vertical. For shell side forced circulation vaporization, the cut
should be horizontal in order to minimize the separation of liquid and vapor.
For double and triple segmental baffles, the preferred baffle orientation is
vertical. This provides better support for the tube bundle than a horizontal cut
which would leave the topmost baffle unsupported by the shell. However this
can be overcome by leaving a small strip connecting the topmost segment
with the bottommost segment around the baffle window between the O.T.L.
and the baffle OD.
Defaults: vertical for double and triple segmental baffles
vertical for shell side condensers
vertical for F, G, H, and K type shells
horizontal for all other cases
 Nozzle Sheet
You should use this sheet to specify the nozzle diameters, if known. Use
nominal pipe sizes. If you do not specify a value, the program assumes
nozzles with a diameter equal to one-third the shell diameter.
The program determines the number of nozzles required based on the
specified shell type and automatically determines the nozzle flange rating.
 Vessel Sheet
Use this sheet to select the material of construction for these items:
Shell
Front head
Tubesheet
Double tubesheet (inner)
Baffles
Tubes
The Qchex program uses the Metals databank to retrieve material properties
and prices. You can use the generic material types such as carbon steel, and
the program will assign actual default material specifications, depending on
the product form. For carbon steel plate, a material specification of SA-516-
70 will be used for an ASME design. Appropriate specifications will be selected
for other design construction codes.
The default material is carbon steel. To select a specific material specification,
click the Databank Search button.
If you want to exclude the pricing of a particular component, for example the
tubes, specify a zero for that material.
You can use the DefMats utility to change the default materials.
See Also
Generic Materials List
 Cladding/Gasket sheet
Use this sheet to specify the material of construction for these items:
Tubesheet cladding
Gaskets - shell side
Gasket -- tube side
The Qchex program uses the Metals databank to retrieve material properties
and prices. You may specify a generic material number or a code for a specific
material specification.
To select a specific material specification, click the Databank Search button.
If you want to exclude the pricing of a particular component, specify a zero
for that material.
You can use the DefMats utility to change the default materials.
See Also
Generic Materials List
 Design Specifications Sheet
Use this sheet to specify these design specifications:
TEMA class
If you want the heat exchanger to be built according to TEMA standards,
select the appropriate TEMA class: B (Default), C, or R. If TEMA is not a
design requirement, then specify Code only, and program will use only the
design code to determine the mechanical design.
Design pressure
Used in the mechanical design calculations, the specified design pressure
influences the shell, head, and tubesheet required thicknesses, and therefore
affects the thermal design. This is in gauge pressure so it is one atmosphere
less than the equivalent absolute pressure.
Design temperature
Used in the mechanical design calculations, the design temperatures influence
the shell, head, and tubesheet required thicknesses, and therefore affect the
thermal design.
Mean metal temperature
These temperatures are used if the program needs to determine if an
expansion joint should be included in the cost.
 Qchex Results
The results section consists of three sections:
Input Summary of the input parameters for the budget estimate.
Warnings and Messages
Design Summary of the pertinent mechanical parameters shown on the
construction portion of the TEMA specification sheet.
Cost Summary reports the budget pricing for the exchanger, including the
cost of material, cost of labor, and mark up
 Mechanical Design
The Qchex program performs an approximate mechanical design of the heat
exchanger components so that the material weight can be determined. Some
of the more significant assumptions used in the analysis are summarized
below.
 Design Pressure
Due to limitations of the analytic procedure at high design pressures,
thicknesses of flanges, tubesheets and flat covers are limited to 12 in. or 300
mm.
The maximum allowable design pressure for a TEMA W-type externally sealed
floating tubesheet is as detailed in TEMA.
 Design Temperature and Allowable Stresses
Design temperatures are limited by the ASME maximum allowable
temperature for the material specified. For design temperatures exceeding
this maximum, the allowable stress is determined at the maximum allowable
temperature and a warning is displayed.
Design temperature for a TEMA W-type unit is limited as detailed in TEMA.
 Corrosion Allowance
Corrosion allowance for cylinders, covers, and tubesheets is determined in
accordance with TEMA.
 Cylinders and Covers
Calculations are to the ASME Code Section VIII Division 1.
Thickness calculations are based on internal pressure loadings and assume
spot radiography.
Flat bolted covers that are not made of carbon steel or low alloy steel are
assumed to be lined with an alloy liner.
Minimum TEMA thicknesses are checked.
Component weights are calculated from finished dimensions, and rough
dimensions are used to determine material costs.
 Tubesheets
Approximate tubesheet thicknesses are calculated in accordance with TEMA.
Tubesheets exceeding 6 in. or 152 mm in thickness and not made of carbon
or low alloy steel are assumed to be clad. The number of clad surfaces is
dependent upon the shell and tube side materials.
Minimum TEMA thicknesses are checked.
The tubesheet thickness is limited to a maximum of 12 in. or 300 mm.
Rough weights are calculated assuming the tubesheet is fabricated from a
square plate.
If a double tubesheet is specified, the shell side tubesheet thickness is based
on the shell side design pressure.
 Flanges
Approximate flange thicknesses are determined using a modified bending
formula.
Ring flanges are assumed for carbon and low alloy construction and for high
alloy flanges less than or equal to 1 in. or 25 mm in thickness. All other
flanges are assumed to be lap joint with a carbon steel ring.
The flange thickness is limited to a maximum of 12 in. or 300 mm.
Rough weights are calculated assuming the flanges are fabricated from forged
rings.
 Tubes
Qchex accesses the same routines which are used in Shell&TubeMech to
determine tube prices for bare or finned tubes.
 Nozzles and Nozzle Flanges
Inlet, outlet, and condensate nozzle sizes can be specified. The program
automatically determines the number of each type of nozzle based on the
shell and head types specified.
Finished and rough weights are based on correlations that consider design
pressure and nozzle diameter.
 Material Prices
The Qchex program accesses the same material price database that is used by
the cost routines in the Shell&TubeMech program. This database contains
several hundred prices and is maintained and updated by Aspen EDR as the
market conditions change. Users can maintain their own material price
database by using the COST database.
The material designators listed in this section are converted to the
appropriate 4 digit material designators used by the Shell&TubeMech and
Metals programs. You can change the correspondence between the 1 or 2 digit
numbers and the 4 digit numbers by using the Defmats database.
Material unit costs are multiplied by the rough weight to determine the
component material cost. The material price for the heat exchanger is
determined by adding all of the component material costs.
If you do not want the price of a particular part of the exchanger to be
included in the total price, you should assign a value of zero for that part
material. For instance, the program would not include the cost of the tubing
in the selling price if you set the tube material to zero.
 Labor Hours
The labor hours required to fabricate the shell and heads of the heat
exchanger are calculated from correlations that were developed by Aspen EDR
based on several hundred labor estimates for a wide variety of exchanger
types and design conditions. These correlations are a function of design
pressure, shell diameter, weight, tube length, and material.
The labor hours for the bundle are determined more precisely using the same
techniques used in the cost estimate portion of the Shell&TubeMech program.
This portion of the program accesses the database of fabrication standards
(machining and drilling speeds). This database is maintained by Aspen EDR or
you can modify this database for your own use by running the Cost database.
Drilling and machining speeds for the tubesheets and baffles are based on the
tubesheet material. Labor hours for loading tubes, tube-to-tubesheet joint
procedures, and bending U-tubes are the same as those calculated by the
Shell&TubeMech cost routines.
 Budget Price
The budget price for the exchanger is calculated by adding the material costs,
labor costs, and markups on material and labor. Labor costs are based on the
total shop fabrication hours and the burdened labor rate. This rate and the
markups on material and labor are the same as used in the Shell&TubeMech
program.
The price is for one heat exchanger and does not include any shipping or
escalation costs.
The Qchex program is intended to be used as a budget estimating tool. The
accuracy of the estimate is dependent upon many factors, including:
Accuracy of the Heat Exchanger Configuration
An estimate where the tube length, tube side, and shell size are known will be
much more accurate than an estimate based on surface area alone.
 Quantity of Materials
The material prices stored in the Aspen EDR standard material price file are
based on average quantity brackets. Very small or very large quantities will
affect the accuracy of the material prices.
 Non-standard Construction
As the construction becomes more non-standard the accuracy of the estimate
decreases.
 Extreme Design Conditions
When the design pressure on one or both sides becomes very high the exact
mechanical design becomes more important. In these cases the
Shell&TubeMech program should be used.
 Premium Materials
When using premium materials (for example titanium) the material price can
be very volatile and highly dependent upon quantity.
 Non-competitive or Rush Orders
The budget estimate is less accurate for non-competitive situations or when
delivery time is a premium.
 Regional Differences
The actual price is dependent upon the country of manufacture and in the
case of the United States and Canada, it is dependent upon the region of
manufacture. The Qchex program does not reflect these regional differences.
 Qchex References
There are relatively few published sources of information on heat exchanger
cost estimating. Most of the logic and much of the data in the Qchex program
have come from the fabrication experience of the engineers at HTFS who
have worked with heat exchanger manufacturers.
For a further understanding of some of the underlying concepts in cost
estimating, see the following publications:
Heat Exchanger Cost Estimating
Computerized Cost Estimation of Heat Exchangers, Bruce Noe‚ and Gregory
Strickler, 21st National Heat Transfer Conference, ASME, 83-HT-62, 1983.
Manufacturing Cost Estimating; Operations and Speeds
Tool & Manufacturing Engineers Handbook, Daniel Dallas, Society of
Manufacturing Engineers, Dearborn, Michigan, 1976.
The Procedure Handbook of Arc Welding, The Lincoln Electric Company,
Cleveland, Ohio, 1973.
Machining Data Handbook, Metcut Research Associates Inc., Cincinnati, Ohio,
1972.
 Props Application Options Sheet
Use this sheet to specify whether you want to retrieve physical properties at a
single temperature point, over a range of temperatures, or to produce a vapor
liquid equilibrium curve with liquid and vapor properties and a heat release
curve.
At one temperature point
If you select the mode that gives the properties at a single temperature, you
need to specify only the starting temperatureand the pressure.
Optionally, you can determine the saturation temperature or saturation
pressure for a single component that has properties stored for both liquid and
gas phases.
To request the saturation temperature, leave the temperature input blank
and specify the desired pressure in the field for pressure. The program will
return the properties at the saturation temperature for the specified pressure.
To request the saturation pressure, specify the desired temperature, and
leave the pressure input field blank. The program will return the properties at
the specified temperature and the pressure that is equal to the vapor
pressure at that temperature.
Over a temperature range:
If you select this mode, Props will give you the properties over a range of
temperatures:
You specify startingand endingtemperatures, the temperature
incrementProps_app_options_temperature_increment, and the
pressureProps_app_options_absolute_pressure.
The maximum number of intervals is 100. Therefore, if you specify a
temperature interval that is smaller than 0.01 times the difference between
the starting and ending temperatures, the program will adjust the
temperature increment to accommodate the full temperature range specified.
Over a temperature range with VLE calculation
If you select this mode, Props will generate a vapor-liquid equilibrium curve
and provide heat load, composition, and physical properties per temperature
increment.
You specify the startingand endingtemperatures, the
pressureProps_app_options_absolute_pressure, and the flowrate
totalProps_app_options_total_flowrate.
The program will divide the condensing range into 20 equal temperature
intervals. A vapor-liquid equilibrium curve will also be provided over the
specified range.
 Property Options
If you select the application option to retrieve properties over a
temperature range with VLE calculations, the Property Options form
appears in the Props input tree. Use this form to specify:
Condensation options
Vaporization options
 Condensation Options Sheet
Use this sheet to specify the following options:
Condensation curve calculation method
The calculation method determines which correlations the program uses to
determine the vapor-liquid equilibrium. The choice of method is dependent on
the degree of non-ideality of the vapor and liquid phases and the amount of
data available.
Condensation curve calculation type
For a condensing stream, you should determine if your case is closer to
integral or differential condensation. The program defaults to integral.
Effect of pressure drop on condensation
The program defaults to calculating the condensing curve in isobaric
conditions (constant operating pressure). If the Aspen EDR Property program
generates the VLE curve, you may specify non-isobaric conditions. The
program allocates the specified pressure drop based on temperature
increments along the condensation/vaporization curve. The vapor/liquid
equilibrium at various temperature points is calculated using an adjusted
operating pressure.
Estimated pressure drop for hot side
If the Aspen EDR Property program generates the VLE curve, the program
uses this pressure drop to adjust the VLE curve.
The VLE calculation program does not permit the condensate to re-flash. If
calculations indicate that this is happening, the program will suggest using a
lower estimated pressure drop.
 Condensation/Vaporization Curve Calculation
Method
The calculation method determines which correlations the program will use to
determine the vapor-liquid equilibrium. The choice of method is dependent on
the degree of non-ideality of the vapor and liquid phases and the amount of
data available.
The methods can be divided into three general groups:
Ideal - correlations for ideal mixtures.
The ideal method uses ideal gas laws for the vapor phase and ideal solution
laws for the liquid phase. You should use this method when you do not have
information on the degree of nonideality. This method allows for up to 50
components.
Soave-Redlich-Kwong, Peng-Robinson, and Chao-Seader - correlations
for non-ideal mixtures which do not require interaction parameters.
The Soave-Redlich-Kwong and Peng-Robinson methods can be used on a
number of systems containing hydrocarbons, nitrogen, carbon dioxide, carbon
monoxide, and other weakly polar components. They can also be applied with
success to systems which form an azeotrope, and which involve associating
substances such as water and alcohols. They can predict vapor phase
properties at any given pressure.
The Chao-Seader method uses Redlich-Kwong equations for vapor phase non-
ideality and an empirical correlation for liquid phase non-ideality. It is used
with success in the petroleum industry. It is recommended for use at
pressures less than 68 bar (1000 psia) and temperatures greater than -18°C
(0°F). The program uses the original Chao-Seader correlation with the
Grayson-Streed modification. There is no strict demarcation between these
two methods since they are closely related. These methods allow for up to 50
components.
Uniquac, Van Laar, Wilson, and NRTL - correlations for non-ideal mixtures
which require interaction parameters.
These methods are limited to ten components. The Uniquac, Van Laar, Wilson,
and NRTL methods require binary interaction parameters for each pair of
components. The Uniquac method also requires a surface parameter and
volume parameter, and the NRTL method requires an additional Alpha
parameter.
The Wilson method is particularly suitable for strongly non-ideal binary
mixtures, for example, solutions of alcohols with hydrocarbons. The Uniquac
method is applicable for both vapor-liquid equilibrium and liquid-liquid
equilibrium (immiscibles). It can be used for solutions containing small or
large molecules, including polymers. In addition, Uniquac interaction
parameters are less temperature dependent than those for Van Laar and
Wilson.
 Condensation Curve Calculation Type
For a condensing stream, you should determine if your case is closer to
integral or differential condensation.
Integral condensation assumes that the vapor and liquid condensate are
kept close enough together to maintain equilibrium, and that the condensate
formed at the beginning of the condensing range is carried through with the
vapor to the outlet. Vertical tube side condensation is the best case of integral
condensation. Other cases which closely approach integral condensation are:
horizontal tube side condensation, vertical shell side condensation, and
horizontal shell side crossflow condensation (X-shell).
In differential condensation the liquid condensate is removed from the
vapor, thus changing the equilibrium and lowering the dew point of the
remaining vapor. The clearest case of differential condensation is seen in the
knockback reflux condenser, where the liquid condensate runs back toward
the inlet while the vapor continues toward the outlet.
Shell side condensation in a horizontal E or J shell is somewhere between
true integral condensation and differential condensation. If you want to be
conservative, treat these cases as differential condensation. However, the
industry has traditionally designed them as integral condensation.
More condensate will be present at any given temperature with integral
condensation versus differential condensation. In the heat exchanger design,
this results in a higher mean temperature difference for integral condensation
compared to differential condensation.
The program defaults to integral.
 Vaporization Options Sheet
Use this sheet to specify the following options:
Vaporization curve calculation method
The calculation method determines which correlations the program uses to
determine the vapor-liquid equilibrium. The choice of method is dependent on
the degree of non-ideality of the vapor and liquid phases and the amount of
data available.
Effect of pressure drop on vaporization
The program defaults to calculating the vaporization curve in isobaric
conditions (constant operating pressure). If the Aspen EDR Property program
generates the VLE curve, you may specify non-isobaric conditions. The
program allocates the specified pressure drop based on temperature
increments along the condensation/vaporization curve. The vapor/liquid
equilibrium at various temperature points is calculated using an adjusted
operating pressure.
Estimated pressure drop for cold side
Specify the estimated cold side pressure drop through the exchanger. The
program uses this pressure drop to adjust the VLE curve. If actual pressure
varies more than 20% from this estimated pressure drop, adjust this value to
the actual and rerun the program.
 Composition Sheet
The Aspen EDR Property Databank consists of over 1500 compounds and
mixtures used in the chemical process, petroleum, and other industries. You
can reference the database by entering the components for the stream on this
sheet.
Select the composition specification - weight flow rate or %, mole flow
rate or %, volume flow rate or % - to determine the basis of the mixture
physical properties calculations. For a single component you can leave
Composition blank. Then use the table to define the stream composition:
Components
For the databank component name, specify either the component name or its
chemical formula. You can specify up to 50 components. Be careful when
using the chemical formula, since several chemicals may have the same
chemical formula but due to different bonding, have different properties.
To search the databank directory, click the Search Databank button.
To enter your own properties for a component, User in the Source field, and
then specify the properties on the Component Properties sheet.
Composition
For VLE calculations this is the composition of the stream in each phase and is
dependant on the Composition Specification.
You must specify the inlet compositions if referencing the databank for
physical properties. If outlet compositions are not specified, the program
assumes the same composition as the inlet. The data for each column is
normalized to calculate the individual components fraction.
Component Type
This field, which is available for all VLE applications, allows you to specify
whether the component is a noncondensable or an immiscible component for
condensing streams, or an inert for vaporizing streams.
If you are not sure of the component type, the program will attempt to
determine the component type. However, in general, it is better to identify
the type if known. If a component does not condense any liquid over the
temperature range in the exchanger, it is best to identify it as a
noncondensable.
Source
This field is currently available for components only when the program is
calculating VLE curves. Databank indicates that all component properties will
be retrieved from one of the Aspen EDR databanks. User indicates that the
physical properties for this component are specified by the user.
Note: percentages do not have to add up to 100, since the program
proportions each to the total.
 Component Properties
Use this sheet to override databank properties or to specify properties not in
the databank. This sheet is available only if a VLE curve has been requested.
The physical properties required for various applications include:
Temperature
It is recommended that you specify property data for multiple temperature
points. The dew and bubble points of the stream are recommended. The
temperatures entered for no phase change fluids should at least include both
the inlet and outlet temperatures. The inlet temperature of the opposite side
fluid should also be included as a 3rd temperature point for viscous fluids.
Multiple temperature points, including the inlet and outlet, should be entered
when a change of phase is present.
Liquid and Vapor Properties
The necessary physical properties are dependent on the type of application. If
you are referencing the databank for a fluid, you do not need to enter any
data on the corresponding physical properties input screens. However, it is
also possible to specify any property, even if you are referencing the
databank. Any specified property will then override the value from the
databank. The properties should be self-explanatory. A few clarifications
follow.
Specific Heat
Specify the specific heat for the component at the referenced temperature.
Thermal Conductivity
Specify the thermal conductivity for the component at the referenced
temperature.
Viscosity
The viscosity requested is the dynamic (absolute) viscosity in centipoise or
mPa*s (note that centipoise and mPa*s are equal). To convert kinematic
viscosity in centistokes to dynamic viscosity in centipoise or mPa*s, multiply
centistokes by the specific gravity.
Density
Be sure to specify density and not specific gravity. Convert specific gravity to
density by using the appropriate formula:
density, lb/ft3 = 62.4 * specific gravity
density, kg/m3 = 1000 * specific gravity
The density can also be derived from the API gravity, using this formula:
density, lb/ft3 = 8829.6 / ( API + 131.5)
Latent Heat
Specify latent heat for change of phase applications.
Vapor Pressure
Specify the vapor pressure for the component. If you do not enter a value for
the vapor pressure, the program will estimate a value.
Surface Tension
Surface tension is needed for vaporizing fluids. If you do not have surface
tension information available, the program will estimate a value.
Molecular /Volume
Specify the molecular volume of the vapor for change of phase applications.
Note, the molecular volume can be approximated by molecular weight /
specific gravity at the normal boiling point.
Molecular Weight
Specify the molecular weight of the vapor for change of phase applications.
Critical Pressure
The critical pressure is the pressure above which a liquid cannot be vaporized
no matter how high the temperature. For mixtures, the critical pressure
should be the sum of the critical pressures of each component weighted by
their mole fractions. This input is required to calculate the nucleate boiling
coefficient. If you do not enter a value for the critical pressure, the program
will estimate a value.
 Interaction Parameters Sheet
The Uniquac, Van Laar, Wilson, and NRTL methods require binary interaction
parameters for each pair of components. This data is not available from the
databank and must be provided by the user.
NRTL Method --Example with 3 components (Reference Dechema)
NRTL "A" Interactive Parameters -Hetran input parameters

NRTL “Alpha” Parameters –Hetran input parameters

Alpha 12 = Alpha 21
Alpha 13 = Alpha 31
Alpha 23 = Alpha 32
NRTL – Conversion from Aspen Properties parameters to Hetran parameters:
Aspen Properties NRTL Parameters – The parameters AIJ, AJI, DJI, DIJ, EIJ,
EJI, FIJ, FJI, TLOWER, & TUPPER in Aspen Properties (not shown in the
following example) are not required for the Hetran NRTL method.
Aspen Properties NRTL Interactive Parameters

“A” Interactive Parameters – Conversion from Aspen Properties to Hetran

“Alpha” Parameters – Conversion from Aspen Properties to Hetran

See Also
Condensation/Vaporization Curve Calculation Method
 NRTL - Alpha parameters
The NRTL method requires binary interaction parameters for each pair of
components and an additional Alpha parameter. This data is not available
from the databank.
See also:
Interaction Parameters
Condensation/Vaporization Curve Calculation Method
 Uniquac - Surface & Volume parameters
The Uniquac method requires binary interaction parameters for each pair of
components and also needs a surface parameter and volume parameter. This
data is not available from the databank.
See also:
Condensation/Vaporization Curve Calculation Method
 Properties Over a Range of Temperatures
If you select this option, PROPS will display the following properties:
Specific Heat of a Liquid & Gas Latent Heat
Viscosity of Liquid & Gas Vapor Pressure
Thermal Conductivity of Liquid & Gas Surface Tension
Density of Liquid & Gas
 VLE
If the VLE calculation was selected, Props will generate a vapor-liquid
equilibrium curve and provide the:
Heat load
Composition
Physical properties per temperature increment
 Databank Structure
The data in the databank is derived from a wide variety of published sources.
For constant properties, for example, molecular weight, the actual value has
been stored in the databank.
For temperature dependent properties, various property specific equations are
used to determine the property at the desired temperature. In these cases,
the coefficients for the equation are stored in the databank.
Vapor pressures are stored using two equations - one for temperatures below
the normal boiling point and one for temperatures above the normal boiling
point.
 Temperature Ranges
There is a separate temperature range of validity stored in the databank for
each property. The temperature range shown in the Databank Directory is the
minimum range for all properties of the respective phase. Therefore, some
properties may have a wider range than shown in the directory.
If you request a property at a temperature outside its valid temperature
range, the program will display a warning and then determine that property
at the appropriate temperature limit (i.e., it will not extrapolate), except for
liquid viscosity and vapor pressure. The program extrapolates above and
below the valid temperature range for vapor pressure. It extrapolates above
for the liquid viscosity.
 Effect of Pressure
The program attempts to correct the gaseous properties as a function of
pressure (liquid properties are assumed to be independent of pressure). To do
this, the program uses a generalized correlation for all components except
water/steam. The generalized correlation is reasonably accurate for most
cases. However, it tends to deviate from actual measured values when the
temperature or pressure approach the critical region.
For water (stored under the names WATER and STEAM), the program uses a
series of specialized equations which predict the corrected steam properties to
within 1% of the values in the ASME Steam Tables.
 Mixtures
The Props program can calculate the composite properties for multicomponent
mixtures for up to 50 components.
Some care should be taken in using the databank for mixtures. Some
mixtures, such as immiscibles or binary mixtures where water is one of the
components, do not conform to the equations. For this reason, some of the
more common water solutions have been included in the databank as single
components.
Mixtures are calculated according to the following techniques:
Density of Liquid

averaged in proportion to the

Latent Heat
weight percent

Molecular averaged in proportion to the mole

Volume percent

Specific Heat of averaged in proportion to the

Gas weight percent

Specific Heat averaged in proportion to the

Liquid weight percent

averaged in proportion to the mole

Surface Tension
percent

Thermal Conductivity of Gas - Friend & Adler Equation

Thermal Conductivity of Liquid - averaged in proportion to the weight percent

Viscosity of Gas - Herning & Zipperer Equation

Viscosity of Liquid - Arrhenius Equation

Nomenclature:
M=molecular
m =viscosity w=weight fraction
weight

k=thermal I=i-th
X=mole fraction
cond. component
y=gas phase mole
r=density m=mixture
fraction
 General Sheet
Use this sheet to specify:
Material name for required components
Temperature range for temperature dependent properties
For the material name you can use the generic material types, such as
carbon steel (default), and the program will assign actual default material
specifications depending on the product form. For carbon steel plate, a
material specification of SA-516-70 will be used for an ASME design.
Appropriate specifications will be selected for other design construction codes.
The selections to the right of the input field are provided for convenience.
Values are not limited to those listed. To search for a specific material
specification, click the Search Databank button. Type the first few characters
to search for a material in the databank.
You can use the DefMats utility to change the default materials.
Many of the properties in the metals databank are temperature dependent.
The starting and ending temperatures determine the temperature range.
Either may be higher or lower. The program will retrieve properties beginning
at the starting temperature, then incrementing the temperature by the
temperature increment value until it reaches the ending temperature or a
maximum of eleven points.
See also:
Generic Material
 Metals Results
The Metals program gives you the option of requesting properties at a single
temperature or at up to ten temperatures. If you request properties at a
single temperature you will also retrieve the properties which are not
temperature dependent.
See also:
Properties Independent of Temperature
Properties Dependent on Temperature
Gasket Properties
Warnings and Messages
 Warnings & Messages
Aspen EDR provides an extensive system of warnings and messages to help
the designer of heat exchanger design. Messages are divided into five types.
There are several hundred messages built into the program. Those messages
requiring further explanation are described here.
Warning Messages: These are conditions, which may be problems, however
the program will continue.
Error Messages: Conditions which do not allow the program to continue.
Limit Messages: Conditions which go beyond the scope of the program.
Notes: Special conditions which you should be aware of.
Suggestions: Recommendations on how to improve the design.
 Properties Independent of Temperature
Material Properties
Property Value

Price 31.75 USD/kg

Density 4512 kg/m3

P No. 52

Group No. —

Specified Min.
379 MPa
Yield

Specified Min.
448 MPa
Tensile

Poisson Ratio 0.32

Material Class Titanium Alloy

 Properties Dependent on Temperature
This part of the output is self-explanatory. Where the property is not stored,
or the temperature exceeds the acceptable range for the material, the
program displays a dash.
 Gasket Properties
Material Properties
Property Value

Price 44.09 USD/kg

Density 2201 kg/m3

Gasket
2.75
Factor m

Min. Design
Seating 25511 MPa
Stress y

Gasket
1.6 mm
Thickness

ASME
2
Column
 Generic Material
Number Generic Material

1 Carbon Steel

2 Low Alloy Steel C 1/2 Mo

3 Low Alloy Steel 1/2 Cr 1/2 Mo

4 Low Alloy Steel Cr 1/2 Mo

5 Low Alloy Steel 1 1/4 Cr 1/2 Mo

6 High Alloy Steel Grade 304

7 High Alloy Steel Grade 304L

8 High Alloy Steel Grade 316

9 High Alloy Steel Grade 316L

10 High Alloy Steel Grade 347

11 High Alloy Steel Grade 310S

High Alloy Steel Grade 310S XM-

12
27 (E-brite)

13 High Alloy Steel Grade 410

14 Nickel Alloy 200

15 Nickel Low Carbon Alloy 201

16 Nickel Alloy 400 (Monel)

17 Nickel Alloy 600 (Inconel)

18 Nickel Alloy 800

19 Nickel Alloy 825 (Inconel 825)

20 Nickel Alloy B (Hastelloy B)

21 Nickel Alloy C (Hastelloy C)

22 Nickel Alloy G (Hastelloy G)

23 Nickel Alloy 20Cb (Carpenter 20)

24 Titanium

Copper-Nickel 70/30 Alloy CDA

25
715

Copper-Nickel 90/10 Alloy CDA

26
706

27 Copper-Nickel Alloy CDA 655

28 Naval Brass Alloy 464

29 Aluminum-Bronze Alloy 630

30 Aluminum Brass Alloy 687

31 Admiralty Alloy 443

33 Zirconium
 Metals References
For a further understanding of subjects relating to METALS, see the following
publications
Material Properties
ASME Boiler and Pressure Vessel Code, Section II, Materials, Part D
Properties, annual
American National Standards Institute (ANSI)
Deutsches Institut für Normung e.V. (DIN)
AD-Merkblätter - Technical Rules for Pressure Vessels, Carl Heymanns Verlag
KG, Berlin, Germany, annual
Verband der Technischen Überwachungs-Vereine e.V. (VdTÜV)
Association Française de Normalisation (AFNOR)
Standards of Tubular Exchangers Manufacturers Association, Seventh Edition,
TEMA, New York, USA, 1988
Equivalent Materials
Worldwide Guide to Equivalent Irons and Steels, ASM International, Metals
Park, Ohio, USA, 1987
Worldwide Guide to Equivalent Nonferrous Metals and Alloys, ASM
International, Metals Park, Ohio, USA, 1987
Stahlschlüssel, C. W. Wegst, Verlag Stahlschlüssel Wegst GmBH, Marbach,
Germany,1992
Material Prices
Metal Statistics - The Purchasing Guide of the Metal Industries, Fairchild
Publications, New York, USA, annual
 Introduction
The Private Chemical Databank program allows you to create your own
chemical properties databank for those fluids not found in the EDR databank.
By selecting the User databank when your private component is referenced in
the EDR programs, the program will automatically access the private
databank when the programs need to retrieve properties from the databank.
The private databank can accommodate up to 400 different fluids.
 Accessing the Private Chemical Databank
Accessing an existing component in the databank
Access the Private Chemical Databank program by selecting Data
Maintenance | Chemical Databank under the Tools menu on the Menu
Bar.
The user can view an existing B-JAC or Standard component in the databank
by:
· selecting B-JAC+ or Standard from the databank option menu,
· then type in the component name, formula, B-JAC ID number, or
synonym,
· if present the component will be shown with the stored properties.
Adding a new component to Private Chemical Databank
Access the Private Chemical Databank program by selecting Data
Maintenance | Chemical Databank under the Tools menu on the Menu
Bar.
To add a new private component to the databank:
· select the User databank
· type the reference name that you wish to call the component
· enter the required physical properties, constants, and curve fitting data
for the component
· select the add button to add the new component to the database
· select the Update button to save the new component and to update the
databank
Adding a new component using an existing component as a template:
· select the B-JAC or Standard databank
· search for similar component by typing in the name or reference to
locate the component
· select the copy button to copy all the property information
· return to the User databank
· type in the name for the new component
· select the Add button to add the component
· select the Paste button to copy the properties from the standard
databank
· modify as necessary the properties that differ from the standard
component
· select the Update button to save the new component and to update the
databank
 Property Reference
Reference the Props section of this user guide for additional information on
the components provided in the B-JAC and standard databanks.
 Property Estimation
Property Curves
Key Equation
0 .... Y = C1 + C2 * T + C3 * T**2 + C4 * T**3 + C5 * T**4
1 .... Y = exp (C1 + C2 / T + C3 * ln(T) + C4 * T ** C5)
2 .... Y = C1 * T ** C2 / (1 + C2 / T + C3 / T ** 2)
3 .... Y = C1 + C2 * exp (-C3 / T ** C4)
4 .... Y = C1 + C2 / T + C3 / T ** 3 + C4 / T ** 8 + C5 / T ** 9
5 .... Y = C1 / C2 ** (1 + (1 - T / C3) ** C4)
6 .... Y = C1 * (1 - T / Tc) **
(C2 + C3 * ( T / Tc) + C4 * (T / Tc) ** 2 + C5 * ( T / Tc) ** 3)
7 .... Y = C1 + C2 * ((C3 / T) / sinh (C3 / T)) ** 2 + C4 *
((C5 / T) / cosh (C5 / T)) ** 2
8 .... Y = exp (ln(C4) – (ln(C2 / C4) / (1 / C1-1 / C3)) / C3 +
(ln(C2 / C4) / (1 / C1 – 1 / C3)) / T)

C1,C2,C3,... Coefficients
T ... Input Temperature in K or R
Tc ... Critical Temperature in K or R
Y ... Calculated Value
** ... Power Function

Property estimation based on NBP

The physical properties program can estimate physical properties for
hydrocarbon components based on their normal boiling point (NBP) and either
the molecular weight or the degrees API. The estimated properties will be
reasonably accurate for the hydrocarbons which meet the following criteria:
The normal boiling point is between 10 and 371 C (50 and 700 F).
The molecular weight is between 50 and 300.
The degrees API is between 5 and 120.
To specify the component name, use one of the following formats:
· NBCxxxMWyyy where xxx is NBP in C and yyy is the molecular weight
· NBFxxxMWyyy where xxx is NBP in F and yyy is the molecular weight
· NBCxxxAPIyyy where xxx is NBP in C and yyy is the degrees API
· NBFxxxAPIyyy where xxx is NBP in F and yyy is the degrees API
Examples: NBC113MW156 NBC98.4API40 NBF323MW70 NBF215.8API44.2
Components outside the ranges specified above will NOT be accepted.
 Introduction
The Private Materials of Construction Databank is a program that allows you
to build and maintain your own databank of materials which supplements the
materials in the Metals databank.
The material can be in the form of plate, pipe, tube, forging, coupling, bolt, or
gasket. Once you assign a material name and store the material properties,
you can then use the new material name in any of the Aspen EDR programs
which allow specific material names (Shell&TubeMech, Metals).
The Private Materials of Construction Databank program provides the
following functions:
· Add a material
· Modify the properties of a material
· Delete a material
· Display or print a list of materials
· Display or print the properties of a material
This program does not require an input data file, since all of the data is stored
in the databank itself. You specify the input data directly into the Private
Materials of Construction Databank program when you run it. The input data
can be specified in either U.S., SI, or Metric units and is divided into three
sections:
· Names
· Constant properties
· Temperature dependent properties
The names are:
· Full name (up to 78 characters)
· Short name (up to 39 characters) for the mechanical design output
· Very short name (up to 24 characters) for the bill of materials
The constant properties include:
· Material type and class
· Price and currency
· Equivalent material numbers for pipe, plate, forging, coupling
· Density
· Minimum thickness
· P number and group number
· External pressure chart
· Minimum tensile and yield strengths
· Maximum thickness for x-ray exemption
· Poisson ratio
· Minimum and maximum diameter for validity
The temperature dependent properties include:
· Thermal conductivity
· Allowable stress
· Yield strength
· Coefficient of thermal expansion
· Modulus of elasticity
· Stress intensity
· Tensile strength
For each of the temperature dependent properties, you can specify from 2 to
21 points, starting from a specified starting temperature, then according to a
specified temperature increment. Each property should also have minimum
and maximum temperatures. If a value is not available for one or more of the
temperature points, you can specify a zero (or leave it blank) and the
databank routine will automatically interpolate using the closest specified
values.
 Currency
This item refers to the currency of the values in the cost files. The original
selections are:
3= French 4= British
1= $US 2= $Canadian
Franc Pound

5= Belgium 6= Deutch
7= Italian Lire 8= Yen
Franc Mark

The default values are already in US dollars. I recommend to always use 1

(US Dollar).
The user can enter the Korean Won in the UOM Control (Unit of Measure
control - the user can enter any currency here). Go to Tools > Data
Maintenance > Units of Measure > Units Maintenance. Fill out the new
currency information. Save the changes. From this point forward, the user
can convert to the new currency. Also, using one of three customizable unit-
sets, the user can default to a currency and other special units.
 Material Type
The number designators used by the program for the material type are:
1= seamless 101= forging (SP = Seamless pipe, ST =
pipe Seamless tube, etc.)

2= seamless
102= coupling
tube

25= welded
151= gasket
pipe

26= welded
165= bolt
tube

51= plate
 Material Class
The number designators used by the program for the material class are:
1= Carbon Steel 2= Low Alloy Steel

3= High Alloy
4= Ni or Ni Alloy
Steel

6= Cu Alloy HT (HT=High
5= Titanium Alloy
Tensile)

7= Nickel Alloy
8= Zirconium
B,C, or G

9= Nickel Alloy HT 10= Cu or Cu Alloy

0=Gasket

The material type and class is important when the user enters his/her own
materials.
 External Pressure Chart Reference
An external pressure chart reference, ASME Section II, Part D, must be
provided for external pressure calculations. The correlation is determine the
number to be entered is as follows:
Material database external pressure chart reference number = X*100 + Y
Where X represents the material type:
X=1 for CS
X=2 for HA
X=3 for NF
X=4 for HT
X=5 for CI
X=6 for CD
Where Y = chart number
Examples: Chart CS-3 = 103 ( X=1, Y=3 )
Chart NFN-16 (old reference was UNF-28.40) = 340 ( X=3, Y=40 )
Example Input to Private Materials of
Construction Databank
 Steps to create a private material
Open Materials Database by selecting Tools / Data Maintenance / Material
Database form the EDR User Interface.
Open one of the existing Code material databases, such as ASME, from the
Database Menu option.
Select a similar material in the Code database to the private material you wish
to create. This will act as a template for the new material.
Select Property / Copy to copy the contents into the buffer.
Select Database / User.
If no user materials exist in the database, you will be asked if you wish to
create a new material. Answer Yes and set the user database number for the
new material. Your new material in the database will be displayed with the
existing properties being used as a template. Proceed to step 8.
If user materials already exist, your existing database items will be displayed.
To copy the template properties, select Property and Paste and then select a
number new material reference number.
Now modify the template properties to generate your new material. If you
have selected a very similar material, you may only need to modify the
material names and the allowable design stresses.
Once all changes have been made, select Save to update the database. Now
this new user material may be referenced from any of the EDR programs.
 Introduction
Exchanger Costing Database is a database maintenance program, designed to
modify and/or print the contents of the labor and material cost files associated
with the Aspen EDR programs which address cost estimation
(Shell&TubeMech, Qchex, and Shell&Tube).
EDR supplies a standard database with each version of the program. When
you make any changes to the database, your changes will always override
any values in the standard database.
To start the Exchanger Costing Database, first change your working directory
to where you want the modified database to reside. This can be the same
directory as the Aspen EDR programs or other user sub-directories. When you
make changes using The Exchanger Costing Database the changes are stored
in your current directory. In this way you can build separate databases on
different directories, which can reflect different costing requirements for
different projects or bids. Access the Exchanger Costing Database program by
selecting Tools from the Menu Bar and then selecting Data Maintenance and
then selecting Costing.
The Exchanger Costing Database gives you access to these databases:
1 General cost and labor adjustment
2 Fabrication and operation standards
3 Material dependent fabrication standards
4 Welding standards
5 Labor efficiency factors
6 Material prices
7 Part numbers for bill of materials and drawings
8 Horizontal support standards
 Labor & Cost Standards
The Exchanger Costing Database contains the following labor and cost
standards.
See Also
General Cost and Labor Adjustment
Fabrication and Operation Standards
Material Dependent Fabrication Standards
Welding Standards
Labor Efficiency Factors
Material Prices
Part numbers for bill of materials and drawings
Horizontal Support Standard Dimensions
 General Cost and Labor Adjustment
This database contains the burdened labor rate (total cost per hour of labor),
the markups on labor and material, and the overall efficiency factors for
welding, machining, drilling, grinding, and assembly.
 Fabrication and Operation Standards
This section allows you to specify over 100 specific fabrication options which
affect the mechanical design and/or the cost. In many cases these options will
establish the defaults for the Shell&TubeMech program where "0 = program."
Included are such things as minimum and maximum material dimensions (e.g.
minimum thickness for nozzle reinforcement pads, minimum and maximum
bolt diameter, and maximum length of pipe) and cost factors (e.g., cost of x-
ray, stress relieving, skidding, and sandblasting). Also included are the
system of measure and the money currency, which apply to all of the
Exchanger Costing Database.
 Material Dependent Fabrication Standards
This file contains the fabrication variables which are dependent upon the type
of material. The materials are divided into ten classes. It includes such items
as machining and drilling speeds, weld deposition rates, maximum dimensions
for various operations, and dimensional rounding factors.
 Welding Standards
Here you can specify the type of welding to be used for each type of vessel
component made from each of ten different material classes. You can choose
from stick electrode, self shielded flux core, gas metal arc, submerged arc,
tungsten inert gas, and plasma welding.
 Labor Efficiency Factors
The cost estimate routines use the data in this file to correct the number of
hours for each labor operation for each type of component. The raw hours
determined by the program are divided by the appropriate efficiency factor.
For example, if the program calculates 20 hours to drill a tubesheet, and the
efficiency factor is 0.5, the estimated number of hours will be 40 hours. The
operations covered are layout, saw, shear, burn, bevel, drill, machine, mill,
form, roll, weld, grind, and assemble.
 Material Prices
This is the database which contains the prices for each material. Prices for
most materials are price per unit weight (e.g. $/lb), except tubing which is
price per unit length for a 19.05 mm (3/4") tube with a 1.65 mm (0.065")
wall thickness. The standard Aspen EDR price is displayed. You can specify a
price for any material, which will then override the standard Aspen EDR price.
 Part numbers for bill of materials and drawings
Default part numbers for every component are provided in this database. You
can modify the default numbers as necessary.
 Horizontal support standard dimensions
You can customize the standard support dimensions used by the programs or
use the default dimensions shown in the database.
 Exchanger Costing Database Example
Here is an example of the Exchanger Costing Database in use:
 Introduction
The Aspen EDR Windows user interface is designed to allow you to export
input and results information into an Excel spread sheet.
This chapter describes how to use these export features. Topics include:
Export features
Exporting results to an existing spread sheet template
Creating your own customized template
Copying and pasting input and results from an EDR application to Excel
Copying and pasting drawings to Excel
Launching an EDR application from Excel
 Export features -- EDR Templates
You can export the program results to an Excel spreadsheet. Several Excel
spreadsheet templates have been provided for your use. You can select one of
the pre-formatted output summaries such as Shell&TubeResults.xlt or you can
select one of the blank templates such as Shell&TubeMechBlank.xlt and
customize your output in Excel.
 Exporting results to an EDR standard summary
template or your customized template
File / Export function - spread sheet created without Excel being open:
First open the EDR program window and open an exchanger design file,
*.EDR. If no results are present, run the program to obtain results.
Select the File | Export to functions from the Menu Bar.
Select the default template or specify which template to open. You can set the
default template from the Tools | Program Settings | Files window.
If you are selecting which template to open, select from the template list,
AirCooledResults, Shell&TubeMechResults, PlateFinSummary, or your
customized template, located in the Aspen Exchanger Design and Rating\Excel
Templates sub-directory.
Select the template to open. Then provide a file name to save the results as a
spread sheet *.xls data file.
Results for the EDR design file will be now be saved in the created Excel
spreadsheet.
 Spread sheet created with Excel open
First, open the EDR program window and open an exchanger design file,
*.EDR. If no results are present, run the program to obtain results.
Open Excel and then open the desired Excel template, AirCooledResults,
Shell&TubeMechResults, PlateFinSummary or your own customized template,
Aspen Exchanger Design and Rating\Excel Templates sub-directory.
For information on how to create your own customized template, click here.
Enable the macros.
Results for the EDR design file will be shown in the Excel spreadsheet. If you
wish to save these results as *.xls file, use the File | Save function in Excel.
 Creating your own customized Template
To create you own customized Excel spreadsheet for the results from EDR,
first make a copy of the *blank.xlt template located in the Aspen Exchanger
Design and Rating\Excel Templates sub-directory and rename it to use as
your template for the customized results form.
Open this new template in Excel.
Enable the macros.
Now by selecting various sections of the output results in EDR, you can drag
and drop into your template. You can change what information is moved from
EDR by right-clicking and selecting Drag-Drop format. You can select to
drag-drop the value or units of measure only or to drag-drop the Caption,
Value, and Units.
For more information on customizing the spreadsheet in Excel, access the
Help provided in Excel.
After your customized template is complete and saved, every time EDR is run,
you can open your customized template to review the results from the run.
 Copying Data from an EDR application to Excel
The following options are available:
Copy Format
Copying Individual Fields
Copying Columns of Information
Copying Tables of Information
Copying Drawings
 Copy Format:
First you need to set the format for the copy. By default, the Drag-Drop
function copies only the value (or values) of information. To reset the format,
select Tools/Program Settings/Advanced and set the copy format.
Value only
Value and units of measure
Caption, value ands units of measure
Units of measure only
 Copying Individual fields:
Select (or highlight) the information you wish to copy by clicking and holding
down the left mouse button on the value and then dragging the mouse cursor
to the desired location in the spread sheet. This ‘drag & drop” method will
move the value as was as any caption and units you have set in the format
described above.
 Copying Columns of information:
Select (or highlight) the column of information you wish to copy by clicking
and holding down the left mouse button on any value in the column and then
dragging the mouse cursor to the desired location in the spread sheet. This
‘drag & drop” method will move the entire column of information as was as
any caption and units that you have set to be copied in the format settings.
 Copying Tables of information:
Select (or highlight) the table you wish to copy. Select the Edit / Copy
function in the Menu Bar. Select the location for the table in the spread sheet.
Select the Edit / Paste function from the Menu Bar in Excel to paste the table
into the spread sheet. This copy & paste method will move the entire table of
information as was as any caption and units that you have set to be copied in
the format settings.
 Copying drawings:
Select the drawing you wish to copy by clicking and holding down the left
mouse button on the drawing then dragging the mouse cursor to the desired
location in the spread sheet. This ‘drag & drop” method will move the drawing
with border into the spread sheet.
 Launching EDR programs from Excel
After you have created you own Excel spread sheet, you can launch the EDR
programs from within the spread sheet.
To run an EDR program from within Excel, using Shell&Tube for this example:
Start Shell&Tube and load the required case.
Run, select from the File | Export to, and then select the required Excel
spreadsheet.
Close Shell&Tube.
Open Excel and reload the spreadsheet.
Start Shell&Tube and reload the case.
While it is loading, Excel and Shell&Tube synchronize the data.
On the spreadsheet, you can change any item marked as an input. This will
cause the corresponding input within the EDR program to updated as well.
From the Aspen EDR toolbar, select Run EDR Case. The EDR program run
and the spreadsheet updated with the results.
 Introduction
This chapter describes how to use the Aspen EDR ActiveX Automation Server.
The topics include:
About the Automation Server
Viewing the Aspen EDR objects
Overview of the Aspen EDR objects
Programming with the Aspen EDR objects
Reference information
This chapter assumes that you are familiar with Microsoft Visual Basic and
understand the concepts of object-orientated programming.
The examples in this chapter use Visual Basic 5.0 and Visual Basic for
Application (VBA) as the Automation Client. Much of the code examples in this
chapter are taken from the example files, which are distributed with the
standard Aspen EDR installation. If you installed Aspen EDR in the default
location, the code examples are located in the Program
Files\AspenTech\Exchanger Design and Rating......\xmp\VB.
The examples use the example problem file LiquidLiquid.BJT, which is
provided with the standard Aspen EDR installation. You will find this file in
Program Files\AspenTech\EXCHANGER DESIGN AND RATING…..\xmp if you
installed Aspen EDR in the default location.
 About the Automation Server
The Aspen EDR Windows user interface is an ActiveX Automation Server. The
ActiveX technology (formally called OLE Automation) enables an external
Windows application to interact with Aspen EDR through a programming
interface using a language such Microsoft’s Visual Basic. The server exposes
objects through the Common Object Model (COM).
With the Automation Server, you can:
connect both the inputs and the results of the Aspen EDR program to other
applications such as design programs of databases.
write your own user interface to control the Aspen EDR program from creating
a new application to printing results of the calculation. With your own
interfaces you can use the Aspen EDR program as a model for your design
plan or use the Aspen EDR program as a part of your design system.
 Using the Automation Server
In order to use the Aspen EDR Automation Server, you must:
Have Aspen EDR installed on your PC.
Be licensed to use Aspen EDR.
The Aspen EDR Automation Server consists of its principal component
BJACWIN.EXE, the core component AtvCoreComponents.DLL and other
supporting components.
The principal component, BJACWIN.EXE, is an out-of-process component, or
ActiveX EXE. You will use this component to deal with Aspen EDR documents
and applications such as Hetran. The core component, ATVDataServer.DLL, is
an in-process component, or ActiveX DLL. You will use this component to
access application objects and data objects. The supporting components
consist of several DLLs and OCXs and are intended to be for internal use only.
If you installed the program in the default location, you will find those files in
the Program File\AspenTech\EXCHANGER DESIGN AND RATING......\xeq.
If you access Aspen EDR objects using strongly typed declaration, you must
reference the Aspen EDR Automation Server in your project before you access
the objects in your program.
To reference the Aspen EDR Automation Server from Visual Basic, or Excel,
open the References dialog box, and check the Aspen EDR Design System box
and ATV core component box as shown here:

If Aspen EDR Design System or ATV core component does not exist in the list,
click Browse and find the Aspen EDR executable directory. Select
BJACWIN.EXE or ATVDataServer.DLL.
If you opened a project used earlier version of the Aspen EDR or the Excel
example file for the Aspen Hetran, HETRANAUTO.XLS, you might find missing
components in your project. In order to use the Aspen EDR objects you should
open the Reference dialog box and check the Aspen EDR Design System box
or the ATV core component box as mentioned earlier.
 Releasing Objects
One object can not be destroyed unless all of the references to the object are
released. Therefore, it is a good practice that you always release the objects
you have referenced when the objects are no longer needed. Releasing an
object is a simple task. This can be done by setting the object to Nothing.
As a general rule, you should release the objects in the opposite sequence as
the objects are referenced. For example:
Dim objBjac As Object
Dim objApp As Object
‘ References objects
Set objBjac = CreateObject(“BJACWIN.BJACApp”)
Set objApp = objBjac.LoadApp(“Shell&Tube”)
...
‘ Release objects
Set objApp = Nothing
Set objBjac = Nothing
 Error Handling
Errors may occur in calling methods or accessing properties of the Aspen EDR
objects. It is important to create an error handler for all code, which accesses
an automation interface. An automation interface may return a dispatch error
for many reasons, most of which do not indicate fatal or even serious errors.
Although any error will normally causes a dialog box to be displayed on the
user’s screen, it is strongly recommended that you write your own error
handler to trap the error in order to exit the application cleanly or proceed
with the next step.
 Viewing the Aspen EDR Objects
The detailed description of the Aspen EDR objects, including properties,
methods and named constants, may be viewed in the Automation Client
Object Browser.
To use the browser, in Visual Basic and Excel, from the View menu, click
Object Browser, the Object Browser will be displayed as shown here:
 Overview of the Aspen EDR Objects
The object exposed by Aspen EDR Automation Server is the BJACApp object.
Through this object other objects and their properties and methods may be
accessed.
 Object Model Diagram
The following diagram provides a graphical overview of the Aspen EDR object
model:
 The BJACApp Object
The BJACApp object is the principal object exposed by Aspen EDR. This object
provides methods and properties such as:
Creating a new or opening an existing Aspen EDR file
Creating a new or getting an existing ATVApp object
Controlling the default settings of the Aspen EDR Window
Enumerating ATVApp objects
Printing results
Saving a file
For more information about the BJACApp object refer to the Reference
Information section.
 Example of Opening an Existing File
The following Visual Basic example creates the Aspen EDR object for an
existing Aspen EDR document, and shows the Aspen EDR Window by setting
the Visible property to True.
Function OpenFile(ByVal FileName As String) As BJACApp
Dim objBjac As BJACApp ' Declare the BJAC object
Set OpenFile = Nothing
On Error GoTo ErrorHandler ' Error trap
Set objBjac = New BJACApp ' Create the BJAC object
If Not objBjac.FileOpen(FileName) Then
MsgBox "Can't open file " & FileName
Exit Function
End If
objBjac.Visible = True ' Show BJAC Window
Set OpenFile = objBjac
Set objBjac = Nothing
Exit Function
ErrorHandler:
MsgBox "Can't create BJAC object"
End ' End the program
End Function
The above code uses Set objBjac = New BJACApp to create an Aspen EDR
object. You can use Set objBjac = CreateObject(“BJACWIN.BJACApp”) to
get the same result.
Note If there is a running Aspen EDR Automation Server on your PC, the
effect of using Set objBjac = New BJACApp or Set objBjac
=CreateObject(“BJACWIN.BJACApp”) only gets a reference to the same
instance of the server.
 The ATVApp object
The ATVApp object exposes the Aspen EDR application, such as Shell&Tube.
Through properties and methods of the ATVApp object you can:
Change the units of measure set
Execute the calculation engine
Check application status
Enumerate inputs and results through data objects collections
Of the many properties and methods in the ATVApp object, there are four
collections for representing data:
Scalars – a collection of ATVScalar objects for representing scalar variables of
input
Arrays – a collection of ATVArray objects for representing array variables of
input
ResultScalars – a collection of ATVScalar objects for representing scalar
variables of results
ResutlArrays – a collection of ATVArray objects for representing array
variables of results
Those data collections provide a bridge to allow you to manipulate data in the
application including changing the units of measure, modifying the value and
so on.
For more information about the ATVApp object refer to the Reference
Information section.
 Example of using an ATVApp object
The following Visual Basic example shows how to get the Aspen EDR Hetran
object from the BJACApp object by opening an existing file, checking the input
status and launching the calculation engine.
Sub AccessHetran()
Dim objBjac As BJACApp ' Declare a BJAC object
Dim objHetran As ATVApp ' Declare a ATVApp object
Dim nRetCode As Integer
On Error Resume Next ' Error trap

' We try to get a BJACApp object

Set objBjac = New BJACApp
If Err.Number <> 0 Then
MsgBox "Can't create BJACApp object!"
End
End If

' First, we check to see if Hetran object is alreay there

' in case there is a BJACApp object running and
' Hetran object is created.
If objBjac.Hetran Is Nothing Then

' If no Hetran object in the current BJACApp object

' then we open the sample file to get a Hetran object
If Not objBjac.FileOpen( _
"C:\Program Files\AspenTech\EXCHANGER DESIGN AND
RATING.....\xmp\LiquidLiquid.BJT") Then
MsgBox "Can't open the file."
GoTo ExitThisSub
End If
End If

' Get the reference to Heatran

Set objHetran = objBjac.GetApp("Hetran")
' Notice that this time we use method GetApp
' to get Hetran object. You can use
' Set objHetran = objBjac.Hetran
' or
' Set objHetran = objBjac.ATVApps("Hetran")

' Check to see if Hetran object is loaded

' this time.
If objHetran Is Nothing Then
MsgBox "Hetran is not created."
GoTo ExitThisSub
End If

' We change the units of measure to SI

objHetran.UomSet = ATV_UOMSET_SI

' Check to see if you can run Hetran

If objHetran.CanRun() Then

' If yes, run Hetran and get the return code

nRetCode = objHetran.Run()

' if we got any error

If nRetCode <> 0 Then
MsgBox "Error in Hetran calculation. Code=" & nRetCode
End If
End If

' Release objects

ExitThisSub:
Set objHetran = Nothing
Set objBjac = Nothing
End Sub
 ATVScalar Object and ATVArray Object
The ATVScalar object and the ATVArray object are used to represent data in
the Aspen EDR objects. As mentioned earlier, the ATVScalar object is used for
scalar data and the ATVArray is used for array data. The ATVApp uses two
pairs of collections containing ATVScalar objets and ATVArray objects to
represent inputs and results, respectively. By accessing the properties and
methods of the data objects, you can:
Return or set a value
Change the units of measure if the data is a physical quantity
Check the status of the variable
For more information about programming with the ATVScalar object and
ATVArray object is provided in the Programming with the Aspen EDR Objects
section. Detailed reference information about the ATVScalar object and
ATVArray object is provided in the Reference Information section.
 Example of accessing data objects
The following Visual Basic example shows how to access a scalar input
variable, change its units of measure and value, and how to retrieve an array
data from results. Note that the example code is stored in the
prjAccessData.VBP VB project in the xmp\VB subdirectory.

Sub Main()
' Variable declarations
Dim objBjac As BJACApp
Dim objHetran As ATVApp
Dim objScalar As ATVScalar
Dim objArray As ATVArray

' We try to get a BJACApp object

Set objBjac = New BJACApp

' We use FileClose to make sure there is no ATVApp object

' loaded since we are going to open the existing sample file
objBjac.FileClose

' Open a BJAC document file to create a Hetran object

objBjac.FileOpen

' Get the Hetran object reference

Set objHetran = objBjac.Hetran
If objHetran Is Nothing Then
MsgBox "Cann't create Hetran object." & vbCrLf & _
"Please try a different file."
End
End

' Get the data object for hot side flow rate
' Notice that "FlRaHS" is the variable name for
' hot side flow rate in Hetran object.
Set objScalar = objHetran.Scalars("FlRaHS")

' We declare a buffer to retrieve current value

' in units "kg/s" no matter what units are actually
' used in the data
Dim xBuf As Single
xBuf = objScalar.Value("kg/s") ' now xBuf is in kg/s

' Let's increase the flow rate by 0.5 kg/s

objScalar.Value("kg/s") = xBuf + 0.5

' Let's try to access Tube OD data object

With objHetran.Scalars("TubeOD")
.Uom = "in" ' Change the units string to "in"
.Value = 0.75 ' Now the tube OD has value of 0.75 in
End With

' Run the Hetran appliation

If objHetran.CanRun Then objHetran.Run

' For example, let's retrieve the shell side pressure drop shown in the
' optimization path.
' Notice that because variable arPresDropShell is an array
' you will need to access the array collection.
Set objArray = objHetran.ResultArrays("arPresDropShell")

' Loop through the array to view every element in the array
Dim I As Integer
For I = 1 To objArray.GetSize()
Debug.Print objArray.Values(I)
Next I

' release objects

Set objScalar = Nothing
Set objArray = Nothing
Set objHetran = Nothing
Set objBjac = Nothing
End Sub
 Programming with Aspen EDR Objects
In this section we will discuss the programming with the Aspen EDR object in
depth. The topics include:
Creating application and file operations
Enumerating objects
Checking status
Controlling the units of measure
Accessing data
Exploring variables
Limitations and restrictions
 Creating Application and File Operations
To create or get a BJACApp object, you can either use
Set objBJAC = new BJACApp
or
Set objBJAC = CreateObject(“BJACWIN.BJACApp”)
Once you have a connection to the BJACApp object, the next step is to create
a new file or open an existing file.
The BJACApp object exposes several methods allowing you to deal with the
Aspen EDR document file including creating a new file, opening an existing
file, printing a file or saving a file.
Using FileNew
One way to create an Aspen EDR application is to use the FileNew method in
the BJACApp object. The code segment below describes how to create a new
file for the Aspen Shell&TubeMech:
Dim objBjac As Object
Dim objTeams As Object
Set objBjac = CreateObject("BJACWIN.BJACApp")
objBjac.FileNew "Teams"
By executing above code a new Teams application is created. The document
containing the new application is named as UNTITLE.BJT. Notice that the
actual document is not created on the disk until the FileSave or FileSaveAs
method is called.
The FileNew method takes the argument AppName as optional. If you just call
the method using the default, in which the argument AppName is an empty
string, then you will see the File New dialog box will appear:

You can check the box next the application to create one or more applications.
Note: Because the BJACApp object can only contain one document at a time,
the FileNew method will unload the current document before creating a new
one. In other words, you can not call the FileNew twice to create two different
applications in the same BJACApp object.
Using LoadApp
The BJACApp object can contain one or more applications. If you want to add
a new application to your existing document, use the LoadApp method. For
example if you want to add a Hetran application in the above example code,
you use
Dim objHetran as ATVApp
Set objHetran = objBjac.LoadApp(“Hetran”)
By executing the above code, a Hetran application object will be added to the
document.
Using FileOpen
The Method FileOpen, in the BJACApp object, is the only way you can open an
existing Aspen EDR document file. The method uses one string argument to
represent the name of the document file to be opened. The argument is
optional. If the default is used or an empty string is assigned, a standard
Windows File Open dialog box will appear, in which the user can browse the
system to select a demand file.
Note: The FileOpen method also unloads the current document before loading
the document supplied. You should save the document if you have made
changes to the document before calling the FileOpen method.
Using FilePrint
Once the calculation is executed successfully, the results will be generated.
And then you can use the FilePrint method to print the results in the format
created by the Aspen EDR program. The following code segment shows how to
use the FilePrint method to print the Shell&TubeMech results after the
calculation succeeded:
If objTeams.Run() = 0 Then
objBjac.FilePrint
End If
By default the FilePrint method will print every result form for every
application in the object. If you want to just print one application, you can
supply the application name in the first argument. For example, to print
Shell&TubeMech only:
objBjac.FilePrint “Teams”
Or if you only want to print a portion of the results, you can set the second
argument to False. For example:
objBjac.FilePrint , False
In this case, the Aspen EDR Print Dialog box will appear as shown here:

This dialog box is the same as you select the Print menu in the Aspen EDR
user interface. You can select any result by checking box next the list item
and change other settings as well.
Using FileSave and FileSaveAs
As mentioned earlier if you use FileNew to create a new file the actual file is
not created in the disk until the file is saved. To save an Aspen EDR document
file to the disk you use the FileSave or FileSaveAs method.
Use the FileSaveAs method or to save a copy of an existing document under a
different name or an existing document to a different drive or path. For
example, supply an existing filename, path to save, and name a new
document:
objBjac.SaveAs “C:\Program File\MyBJACFile\Exchan ger.BJT”
Use the FileSave method to save the document in the same filename, or in
the default name defined by the program. For example:
objBjac.Save
It is strongly recommended that you use the FileSaveAs method to save the
document in a desire filename if the document was newly created using the
FileNew method. Because the default filename defined by the program is
UNTITLE.BJT.
The argument of the FileSaveAs method can be omitted. If do so, a standard
“Save As” Windows dialog box will appear and you will be able to specify any
filename or file path.
 Enumerating Objects
The Aspen EDR Automation Server provides following collections to keep track
of the objects:
Application collection: BJACApp.ATVApps
Scalar data collection for input: ATVApp.Scalars
Array data collection for input: ATVApp.Arrays
Scalar data collection for results: ATVApp.ResultScalars
Array data collection for results: ATVApp.ResultArrays
You can use For Each …Next to enumerate the objects in the collections,
without losing any part of the information for the BJACApp object. This is
particularly important if you want to generate your own database to store
input and results information rather than using the Aspen EDR document, or
create your own graphic user interface to access the Aspen EDR objects.
The following example code prints names and values for all scalar variables in
the input:
Dim objApp as ATVApp
Dim objScalar as ATVScalar
…
For Each objScalar In objApp.Scalars
Debug.Print objScalar.Name, objScalar.Value
Next
 Checking Status
Checking Status for an application or for a data object is important when you
want to know whether you have made changes to the application, whether
you can run the program, or whether the results are present.
Using IsSaved
The IsSaved property is provided in the BJACApp object and the ATVApp
object. You can use this property to check to see if any change in the input of
the document has been made and the changes have not been saved. This is
particularly useful when changes have been made and you need to save these
changes.
The following code gives an example that shows how to use the property:
Private Sub SaveFile(ByVal objBjac as BJACApp )
If Not objBjac.IsSaved Then
objBjac.FileSave
End If
End Sub
If you just want to check to see if a particular application has been modified
or not, you can query the ATVApp.IsSaved property. For example:

Dim objHetran as ATVApp

…
If Not objHetran.IsSaved Then
objBjac.FileSave
End If
Notice that once the document is saved the IsSaved property will return a
value of True to reflect the change of the status.
Using IsComplete
The IsComplete property is used to check the completion status for an
application or check for required input data. The Aspen EDR object provides a
variety of comprehensive algorithms checking the completion status for
applications based on various input conditions. The IsComplete property
returns a value of True to indicate the status is complete.
Use the IsComplete property in an ATVApp object to check the completion
status for the application. For example:
Dim objHetran as ATVApp
…
If objHetran.IsComplete then
‘ the input is complete,
…
End if
Use the IsComplete property in a data object to check to see if the input data
is complete. For an input data, if the data is not required then the property
always returns True. If the data is required and the value is missing then the
IsComplete property returns False.
The following example shows how to find an incomplete data in the input
scalar objects:
Function FindIncompleteData(ByVal objApp As ATVApp) As ATVScalar
Dim objScalar As ATVScalar

' Loops through the scalar objects

For Each objScalar In objApp.Scalars

' Checks to see if the data is complete

If Not objScalar.IsComplete Then

' Found the first incomplete data, return the data and exit
Set FindIncompleteData = objScalar
Exit Function
End If
Next
End Function
 Controlling the Units of Measure
The Aspen EDR user interface has provided a solution to handle the
complexity of different units of measure. Through the Aspen EDR user
interface, you can add your own units, or change any existing units in the
units table, and then use these new or modified units for input field,
calculation or printed results without even closing the application window.
The Aspen EDR Automation Server provides you three different levels to
control the units of measure in your program:
The UomSet property in the BACApp object
The UomSet property in the ATVApp object
The Uom property in the data objects
UomSet in BJACApp Object
Use the UomSet property in the BJACApp object to view or change the units
of measure set for the BJACApp object. For example:
Dim objBjac as BJACApp
Dim nSet as Integer
…
‘ Gets the current units set
nSet = objBjac.UomSet

‘ Checks to see if it’s SI, if not then change it to SI

if nSet <> ATV_UOMSET_SI then objBjac.UomSet = ATV_UOMSET_SI
Note: The UomSet property is the default units set for application objects.
Changing UomSet in the BJACApp object will not have any effect on the
applications that are already created.
UomSet in ATVApp Object
Use the UomSet property in an ATVApp object to return or change the units
of measure set for the application. For example:
Dim objApp as ATVApp
...
‘ Sets the units set to user defined SET1
objApp.UomSet = ATV_UOMSET_SET1
Note: By changing the UomSet in the ATVApp object, the units of physical
quantity data objects in the application will be changed to the units defined in
the units set table. Consequently the values of these data will be converted
appropriately to the new units if the current units set is different. Also, you
will notice that the units controls in the Aspen EDR user interface will prompt
in accordance with the changes.
Uom in ATVScalar Object and ATVArray Object
Use the Uom property in the ATVScalar and ATVArray objects to view or
change the units of measure for the data. For example:
Dim objHetan as ATVApp
…
‘ Changes the units of hot side flowrate to “lb/s”
objHetran.Scalars(“FlRaHS”).Uom = “lb/s”

Notes:
The Uom property only applies to the physical quantity data, for example,
temperature and pressure.
The Uom property is a string. You must assign an existing unit string to the
data. The unit string remains unchanged if an invalid unit string is supplied.
Changing the unit string will not result in the value being converted.
 Accessing Data
The data in the Aspen EDR applications can be accessed through the two data
objects: ATVScalar and the ATVArray. You can not create a new data object,
but you can access all the attributes including changing the value or unit
string for all the data objects. To access a data of interest, one possible
method is as follows:
Locate the variable of interest.
Find out the attributes for the variable. Especially, you need to know the
variable is a scalar or an array, and input or result.
Get the reference to the data object using the appropriate data object
collection.
View or change the value or unit string if necessary.
Detailed information about the data objects is given in the Reference
Information section.
 Exploring Variables
In order to access the data of interest in an Aspen EDR design, you need to
locate the variables of interest in the system. To do this, you can use the
Application Browser together with the Variable List Window in the Aspen EDR
User Interface to navigate the data.
In the Aspen EDR user interface, every application, for example, Hetran, is
represented in an Application Browser. The Application Browser has a tree
structure and contains the visual representation for inputs and results in a
series of forms. On each form, for input and results, each data control is
connected a data object, and each data has a variable associated with it. The
Variable List window will list all the variables behind the form.
To open the Variable List Window, from the View menu, click Variable List.

The Variable List Window displays the attributes including names, variable
type, current values, and descriptions for all the variables used on the form.
Notice that the indicates an input variable, and the indicate a result
variable.
Another way to locate a variable is to view the variable attributes in the
description pane on the Application Browser by clicking a control.
To show the variable attributes on the description pane:
From the Tool menu, click the Program Setting to display the program setting
dialog box.
Click the Advanced tab, and check the option Show Variable Attributes on the
Description Pane. Click OK to close the dialog box.
On the Application Browser, display any input or results form.
Click a control on the form to see the attributes of the variable associated
with the control, which are displayed on the description pane.
For example:
 Limitations and Restrictions
The Aspen EDR Automation Server is a single threaded object and only one
copy of its instance can be created at a time. In other words, if the server is
running before you create a BJACApp object, using following code:
Set objBJAC = New BJACWIN.BJACApp
or
Set objBJAC = CreateObject(“BJACWIN.BJACApp”)
will share with the existing thread.
The BJACApp object can only deal with one document at a time. If you try to
create another new document or open another existing document, the
consequence is that the program will unload the current document first.
Although multiple ATVApp objects can co-exist in the BJACApp object, you can
only create one kind of the application object at a time. For example, the
Shell&Tube object is not allowed to have more than one copy. In other words,
you can not create two Shell&Tube applications in the same BJACApp object.
Only the BJACApp object can be created in your code. Other objects can only
be referenced. The object collections can only be referenced. You can not add
any item to the collections. If you try to do so, it may cause unpredictable
results.
 Reference Information
The topics in this section includes:
Lists of the members for each exposed Aspen EDR classes
Member descriptions
Error descriptions
 Members of Class BJACApp
Name Member Type Data Type Description

Returns the ATVApp objects

ATVApps Property (Get) C ollection
collection

Returns/sets a value that

ExecutionC ontrolEnabled Property (Get/Let) Boolean
determines execution control

FileC lose Sub C loses the current document

FileExit Sub Terminates the program

FileNew Function Boolean C reates a new document

FileOpen Function Boolean Opens an existing document

FilePrint Sub Prints the results

FileSave Function Boolean Saves the document

Saves the document to a different

FileSaveAs Function Boolean
file

GetApp Function Object Returns an ATVApp object

Returns the current document

GetFileName Function String
filename

GetFilePath Function String Returns path name

GetList Function Long Retrieves static list information

GetListC ollection Function Long Retrieves static list information

GetUomString Function String Returns a valid units string

GetVersion Function String Returns the version information

Hide Sub Hides the UI Windows

Returns a Boolean value

IsSaved Property (Get) Boolean determining whether the document
is saved

Returns/sets the language for the

Language Property (Get/Let) Long
UI Windows

LoadApp Function Object C reates or gets an ATVApp object

Minimize Sub Minimize the UI Windows

Show Sub Show the UI Windows

Returns the ATVApp object for

Teams Function Object
Shell&TubeMech

Returns/sets the default units of

UomSet Property (Get/Let) Long
measure set

Returns/sets a value that controls

Visible Property (Get/Let) Boolean
the visibilty of the UI Windows
 Members of Class ATVApp
Name Member Type Data Type Description

Returns the collection of array

Arrays Property (Get) C ollection
data objects for input

Returns a value determining

C anRun Property (Get) Boolean whether the calculation can be
executed

DisplayDrawing Sub Displays the given drawing

Exports drawings to AutoC AD DXF

ExportToDXF Function Boolean format file and returns True if
successful

Returns a value indicating whether

HasResults Property (Get) Boolean
the results are present

Returns a value indicating whether

IsC omplete Property (Get) Boolean
the required data are inputted

Name Property (Get) String Returns the name of the object

Parent Property (Get) Object Returns the parent object

Returns the collection of array

ResultArrays Property (Get) C ollection
data objects for results

Returns the collection of scalar

ResultScalars Property (Get) C ollection
data objects for results

Runs the calculation engine and

Run Function Long
returns the status

Runs the calculation engine with

Run2 Function Long the given run type, and returns the
status

Gets fired when the calculation is

RunFinished Event
done

Returns the collection of scalar

Scalar Property (Get) C ollection
data objects for input

Returns or sets the units of

UomSet Property (Get/Let) C ollection
measure set for the application
 Members of Class ATVScalar
Name Member Type Data Type Description

Returns a value that indicates the

C ategory Property (Get) Long
data category

Returns a value that indicates

IsC omplete Property (Get) Boolean whether the required data is
inputted

IsEmpty Function Boolean C heck to see if the data is empty

Returns the name of the data

Name Property (Get) String
object

Parent Function (Get) Object Returns the parent object

Returns the physical quantity

name if the data is a physical
PQOrListType Property (Get) String
quantity, or the name of the list if
the data is a static list.

Returns a supplemental
Text Property (Get) String
information

Returns a string that represents

Uom Property (Get/Let) String the unit for a physical quantity
data.

Value Property (Get/Let) Variant Returns/sets a value for the data

 Members of Class ATVArray
Name Member Type Data Type Description

Returns a value that indicates the

C ategory Property (Get) Long
data category

Insert Sub Insets an element in the array

Returns a value that indicates

IsC omplete Property (Get) Boolean whether the required data are
inputted

C heck to see if the given element

IsElementEmpty Function Boolean
is empty

C heck to see if the whole array is

IsEmpty Function Boolean
empty

Name Property (Get) String Returns the name

Parent Property (Get) Object Returns the parent object

Returns the physical quantity

name if the data is a physical
PQOrListType Property (Get) String
quantity, or the name of the list if
the data is a static list.

Removes an element from the

Remove Sub
array

Returns a supplemental
Text Property (Get) String
information

Returns a string that represents

Uom Property (Get/Let) String the unit for a physical quantity
data.

Returns/sets a value for the given

Values Property (Get/Let) Variant
element
 Member Descriptions
The descriptions of the Methods, Properties, and Events in the EDR classes
follow.
Methods
DisplayDrawing
ExportToDXF
FileClose
FileExit
FileNew
FileOpen
FilePrint
FileSave
FileSaveAs
GetApp
GetFileName
GetFilePath
GetListCollection
GetSize
GetVersion
Hide
Insert
IsElementEmpty
IsEmpty
LoadApp
Minimize
Remove
Run
Run2
Show
Properties
ExecutionControlEnabled
Language
Uom
UomSet
Value, Values
Visible
Read-Only Properties
Arrays
ATVApps
CanRun
Category
HasResults
IsComplete
IsSaved
Name
Parent
PQOrListType
ResultArrays
ResultScalars
Scalars
Text
Event
RunFinished
 Aerotran Method
Gets a reference to an ATVApp object that represents the Aerotran
application.
Applies To BJACApp Object
Syntax object.Aerotran
Data Type Object
Remarks: This method is the same as the statement:
Set objAerotran = object.GetApp(“Aerotran”).
 Arrays Property (Read-only)
Gets a reference to the collection containing array data objects for input in an
ATVApp object.
Applies To ATVApp Object
Syntax object.Arrays
Data Type Collection
 ATVApps Property (Read-only)
Gets a reference to the collection containing the ATVApp objects in the
BJACApp object.
Applies To BJACApp Object
Syntax object.ATVApps
Data Type Collection
Remarks: In the Aspen EDR object, an application object named “UTILITIES”
is always loaded for the internal service purpose. This internal application
object has no visual representation and will stay the BJACApp object as long
as a document is loaded.
 CanRun Property (Read-only)
Returns a Boolean value that determines whether or not the calculation
engine can be executed.
Applies To ATVApp Object
Syntax object.CanRun
Data Type Boolean
Remarks If the property ExecutionControlEnabled in the BJACApp object is
True, the CanRun method will be controlled by the completion of the input. In
this case, if the IsComplete method in the application object returns True,
then the CanRun also is True. However, if the
BJACApp.ExecutionControlEnabled is False, the CanRum always returns True.
 Category Property (Read-only)
Returns a long integer that determines the category for the data object.
Applies To ATVScalar Object, ATVArray Object
Syntax object.Category
Data Type Long
Remarks The Aspen EDR object has defined following seven constants for the
data category:
VB
Constant Value Data Description
Type

Physical quantities, such as temperature and

ATV_DATAC ATEGORY_PQ 0 Single
pressure.

StaticList, such as TEAM C lass. A StaticList data

has a list of items from which the use can
ATV_DATAC ATEGORY_LIST 1 Long
select one and the index of the item selected
will be returned as the value of the data.

ATV_DATAC ATEGORY_NUM 2 Single Numeric number

ATV_DATAC ATEGORY_STR 3 String C haracter string

ATV_DATAC ATEGORY_BOOL 4 Boolean Boolean data

ATV_DATAC ATEGORY_VOC 5 String Vocabulary (internal use only)

ATV_DATAC ATEGORY_MSG 6 String Message (internal use only)

 DisplayDrawing Method
Displays the given drawing.
Applies To ATVApp Object
Syntax object.DisplayDrawing (hWndClient, DrawingID)
Parameters
Required. A long value representing the handle of client window, on
hWndC lient Long
which the drawing will be displayed.

Required. A long value representing the drawing to be displayed.

DrawingID Long
See Drawing ID Definitions below for details.

Drawing ID Definitions
ID Description Hetran Shell&TubeMech Aerotran Ensea

10 Outline x x x

11 Setting plan x x

Material
20 x
specifications

30 Sectional x

Bundle
40 x
layout

Tubesheet
50 x x x x
layout

60 Shell x

61 Shell A x

62 Shell B x

70 Shell cover x

80 Front head x

90 Rear head x

100 Floating head x

110 Bundle x

120 Baffles x

130 Flat covers x

Front
140 x
tubesheet

Rear
150 x
tubesheet

Expansion
160 x
joint

171 Gaskets A x

172 Gaskets B x
173 Gaskets C x

Body flanges
181 x
A

Body flanges
182 x
B

Body flanges
183 x
C

Body flanges
184 x
D

Body flanges
185 x
E

Body flanges
186 x
F

Vertical
190 x
supports

Bottom front
191 x
supports

Top front
192 x
Supports

Bottom rear
193 x
Supports

Top rear
194 x
supports

200 Weld details x

Example
The following code shows how to display the Setting Plan drawing on a VB
PictureBox control. To try this example, paste the code into the Declarations
section of a form with a PictureBox control, Picture1, and two command
bottoms, Command1 and Command2:
Dim objBjac As Object
Dim objApp As Object

Private Sub Command1_Click()

' Displays a FileOpen dialog box and let
' user to select a BJAC document file
' Note: the BJAC document must contain Teams
' in order to test the drawing
objBjac.FileOpen

' Releases the object first

Set objApp = Nothing
' Gets a Teams reference
If objApp Is Nothing Then Set objApp = Nothing
Set objApp = objBjac.GetApp("Teams")

If objApp is Nothing Then

Beep
MsgBox "The document doesn't contain Teams." & vbCrLf & _
"Please try a differnet file."
Else
' Displays the setting plan
' Note: 11 is the drawing ID for setting plan
objApp.DisplayDrawing Picture1.hWnd, 11
End If

' Displays the setting plan

' Note: 11 is the drawing ID for setting plan
If Not objApp Is Nothing Then
objApp.DisplayDrawing Picture1.hWnd, 11
End If
End Sub

Private Sub Command2_Click()

Unload Me
End Sub

Private Sub Form_Load()

' Creates a BJAC object

Set objBjac = CreateObject("BJACWIN.BJACApp")

' Checks the error

If objBjac Is Nothing Then
Beep
MsgBox "Can't create BJAC object"
Unload Me
End If
End Sub

Private Sub Form_Unload(Cancel As Integer)

Set objApp = Nothing
Set objBjac = Nothing
End Sub

Private Sub Picture1_Paint()

' Since the drawing doesn't get repainted automatically,
' we need to repaint.
If Not objApp Is Nothing Then objApp.DisplayDrawing Picture1.hWnd, 11
End Sub
 ExecutionControlEnabled Property
Returns or sets a Boolean value that determines whether or not the program
can take control of the calculation execution. When set to True, the input
must be complete in order to execute the calculation engine. When set to
False, the calculation engine can be launched at any time.
Applies To BJACApp Object
Syntax object.ExecutionControlEnabled [ = Boolean ]
Data Type Boolean
 ExportToDXF Method
Exports the drawings to AutoCAD DXF format file and returns True if the
function succeeds.
Applies To ATVApp Object

Syntax object.ExportToDXF( [DrawingID][,DXFFileName])

Data Type Boolean
Parameters
Optional. A long value representing the drawing to be
exported. If omitted, all the drawings in the object will
DrawingID Long
be exported. For detailed definitions for DrawingID, see
the DisplayDrawing method.

Optional. A string value representing the filename

drawing to be exported. If omitted, the current
document file will be used.
DXFFileName String
Note: If DrawingID is omitted, each drawing will be
saved to a file with corresponding DrawingID appended
to the DXFFileName.
 FileClose Method
Closes the current open document.
Applies To BJACApp Object
Syntax object.FileClose
Remarks The FileClose method will close all of the application user interface
windows associated with the open document and destroy all the objects
associated with the document as well.
Note: Prior to calling this method, you should release all the objects you have
referenced in the code except the BJACApp object.
Example
Dim objBjac As Object
Dim obhApp As Object
Dim objDat As Object
...
‘ Gets a reference to the App object
Set objApp = objBjac.ATVApps(“Aerotran”)

‘ Gets a reference to a data

Set objDat = objApp.Arrays(“BJACDBSymbHS”)
...
‘ Release the references prior to calling FileClose
Set objApp = Nothing
Set objDat = Nothing

‘ Call FileClose to destroy the document

objBjac.Close
...
 FileExit Method
Destroys all the objects in the BJACApp object.
Applies To BJACApp Object
Syntax object.FileExit

Remarks The FileExit method will perform following steps:

· Close all of the application user interface windows associated with the
open document if the necessary.
· If there is no running BJACWIN.EXE prior to the BJAC object is created in
your code, the FileExit method will also destroy the Aspen EDR user interface
main window.
Note 1) Prior to calling this method, you should release all the objects
referenced in your code in the opposite sequence of referencing. 2) Instead of
calling this method, you could simple use Set objBjac = Nothing in your
code.
 FileNew Method
Creates a document and returns a Boolean value indicating whether or not
the process succeeded.
Applies To BJACApp Object

Syntax object.FileNew( [AppName])

Data Type Boolean
Parameters
Optional. A string value representing the name of an
application to be created. If omitted, the File New
AppName String
Dialog box appears and user can select one or more
applications to create.
 FileOpen Method
Opens an existing document from the disk and returns a Boolean value
indicating whether or not the process succeeded.
Applies To BJACApp Object
Syntax object.FileOpen( [Filename])
Data Type Boolean
Parameters
Optional. A string value representing the name of an
existing document file to be opened. If omitted, the
Filename String standard Windows FileOpen Dialog box will be
displayed to allow user to open any existing
document.
 FilePrint Method
Prints the results for the document if results are present.
Applies To BJACApp Object
Syntax object.FilePrint( [AppName], [PrintAll])
Parameters
Optional. A string value representing the name of an
AppName String application to be printed. If omitted, every application
will be printed.

Optional. A Boolean value that determines whether or

not to print all of the results. If False, then the Print
PrintAll Boolean
Selection Dialog box appears and user can select the
results to print.
 FileSave Method
Saves the current document file to a disk without changing the name and
returns a Boolean value indicating whether or not the process succeeded.
Applies To BJACApp Object
Syntax object.FileSave
Data Type Boolean
 FileSaveAs Method
Saves a copy of the document to the disk using a different name or path and
returns a Boolean value indicating whether or not the process succeeded.
Applies To BJACApp Object
Syntax object.FileSaveAs( [Filename])
Data Type Boolean
Parameters
Optional. A string value representing the full path name
of the document to be saved. If omitted, the standard
Filename String
Windows FileSaveAs Dialog box appears and user will
be able to specify the name through the dialog.
 GetApp Method
Returns a reference to the specified ATVApp object if succeeded or Nothing if
failed.
Applies To BJACApp Object
Syntax object.GetApp( Appname )
Data Type Object
Parameters
Required. A string value representing the
Appname String
name of the application.
 GetFileName Method
Returns a string value representing the full path name of the open document.
Applies To BJACApp Object
Syntax object.GetFileName
Data Type String
 GetFilePath Method
Returns a string value representing the file path information.
Applies To BJACApp Object
Syntax object.GetFilePath(Type )
Data Type String
Parameters
Required. A Long value indicating the type of information
to be retrieved. Accepted values are:
0 - The program installation folder name.
1 - Executable files folder name
Type Long 2 - Help files folder name
5 - C urrent open document name
10 - Full path name for the static list database
11 - Full path name for the units of measurement
database
 GetListCollection Method
Retrieves information from a static list and returns the number of items in the
list if succeeded or 0 if failed.
Applies To BJACApp Object
Syntax object.GetListCollection(ListName, ListItems, ListIndices )
Data Type Long
Parameters
Required. A string value representing the name of the
ListName String
static list to be retrieved

Required. A collection to be used to store the items in

ListItems C ollection
the list.

Required. A collection to be used to store the

ListIndices C ollection
corresponding indices for the list

Example
The following code shows how to retrieve the shell type list in the Aspen EDR
static list database:
Dim objBjac As Object
Dim ListItems As Collection
Dim ListInices As Collection
Dim nItems As Long
Dim I as Long
...

nItems = objBjac.GetListCollection(“ShellType”,ListItems,ListIndices)
For I = 1 to nItmes
Debug.Print ListIndices(I),”,” ListItems(I)
Next I
...

The code will print following results on the debug window:

0, Program
1, E – one pass shell
2, F - two pass shell with long. baffle
3, G - split flow
4, H - double split flow
5, J - divided flow (nozzles: 1 in, 2 out)
6, K – kettle
7, X – crossflow
8, V - vapor belt
9, J - divided flow (nozzles: 2 in, 1 out)
 GetSize Method
Returns the number of elements in the array data object.
Applies To ATVArray Object
Syntax object.GetSize
Data Type Long
 GetVersion Method
Returns a string value representing the current version information of the
program.
Applies To BJACApp Object
Syntax object.GetVersion
Data Type String
 HasResults Property (Read-only)
Returns a Boolean value that indicates whether or not the results are present.
Applies To ATVApp Object
Syntax object.HasResults
Data Type Boolean
 Hetran Method
Gets a reference to an ATVApp object that represents the Hetran application.
Applies To BJACApp Object
Syntax object.Hetran
Data Type Object
Remarks The following statements will have the same results:
Set objApp = objBjac.Hetran
Set objApp = objBjac.GetApp(“Hetran”)
Set objApp = objBjac.ATVApps(“Hetran”)
 Hide Method
Hides the Aspen EDR user interface.
Applies To BJACApp Object
Syntax object.Hide
Remarks This is the same as if you use the statement: object.Visible = False
 Insert Method
Inserts an element into the array data object.
Applies To ATVArray Object
Syntax object.Insert(Data [,Index] )
Parameters
Data Variant Required. A variant value to be assigned

Optional. A Long value indicating where the new

Index Long element should be inserted after. If omitted, the new
element will be added to the last.
 IsComplete Property (Read-only)
Returns a Boolean value that indicates whether or not the required data are
inputted.
Applies To ATVApp Object, ATVArray Object, ATVScalar Object
Syntax object.IsComplete
Data Type Boolean
 IsElementEmpty Method
Returns a Boolean value that indicates whether or not an element in the
array data is empty.
Applies To ATVArray Object
Syntax object.IsElementEmpty(Index )
Data Type Boolean
Parameters
Required. A Long value indicating the
Index Long
element to be checked.

Remarks Use this method to check an individual element in the array. Use
the IsEmpty method to check the entire array.
 IsEmpty Method
Returns a Boolean value that indicates whether or not the data is empty.
Applies To ATVArray, ATVSalar Object
Syntax object.IsEmpty
Data Type Boolean
Remarks Use this method to check to see if the data is empty or not. For
ATVArray objects, the return is True only if all of the elements in the array
are empty.
 IsSaved Property (Read-only)
Returns a Boolean value that indicates whether or not the new changes made
to the input of the open document have been saved.
Applies To BJACApp, ATVApp Object
Syntax object.IsSaved
Data Type Boolean
 Language Property
Returns or sets a Long value that determines the language used in the
program.
Applies To BJACApp Object
Syntax object.Language [ = Setting% ]
Data Type Long
Remarks Currently, the Aspen EDR program has assigned following constants
for language:
Constant Value Description

ATV_LANGUAGE_ENGLISH English

ATV_LANGUAGE_GERMAN German

ATV_LANGUAGE_SPANISH Spanish

ATV_LANGUAGE_FRENC H French

ATV_LANGUAGE_ITALIAN Italian

ATV_LANGUAGE_C HINESE C hinese

ATV_LANGUAGE_JAPANESE Japanese
 LoadApp Method
Gets or creates an ATVApp object the specified application. It returns the
reference to the object if the method succeeded or Nothing if failed.
Applies To BJACApp Object
Syntax object.LoadApp( Appname )

Data Type Object

Parameters
Required. A string value representing the name of the
Appname String
application.

Remarks The LoadApp method will create the object if the specified ATVApp
object is available in the BJACApp object. If the object already exists, the
method will act like the GetApp method.
 Minimize Method
Minimize the Aspen EDR user interface Windows
Applies To BJACApp Object
Syntax object.Minimize
 Name Property (Read-only)
Returns a string value representing the name of the object.
Applies To ATVApp Object, ATVArray Object, ATVScalar Object
Syntax object.Name

Data Type String

Remarks When used for an ATVApp object, it returns the name for the
application, for example, Shell&Tube. When used for an ATVArray object or
ATVScalar object it returns the variable name associated with data.
 Parent Property (Read-only)
Returns a reference to the parent object.
Applies To ATVApp Object, ATVArray Object, ATVScalar Object
Syntax object.Parent
Data Type Object
Remarks It returns a BJACApp object the ATVApp object, and returns an
ATVApp object for the data objects.
 PQOrListType Property (Read-only)
Returns a string value that represents the name of the physical quantity or
static list assigned to the data.
Applies To ATVScalar Object, ATVArray Object
Syntax object.PQOrListType
Data Type String
Remarks The PQOrListType property is used only for data that are physical
quantities or lists. The property returns the name of the physical quantity or
the list.
Example
The following example shows how to access the PQOrListType property:
Dim objHetran As ATVApp
...
‘ For a PQ data
Debug.Print objHetran.Scalars(“FlRaHS”).PQOrListType
‘ For a List data
Debug.Print objHetran.Scalars(“ApplTypeHS”).PQOrListType
...
The result of these statements prints following string on the Debug Window:

MassFlowrate
ApplicationTypeHS
 Remove Method
Removes an element from an array data object.
Applies To ATVArray Object
Syntax object.Remove([Index] )
Parameters
Optional. A Long value indicating the element
Index Long to be removed in the array. If omitted, the
last element will be removed.
 ResultArrays Property (Read-only)
Gets a reference to the collection containing array data objects for results in
an ATVApp object.
Applies To ATVApp Object
Syntax object.ResultArrays
Data Type Collection
 ResultScalars Property (Read-only)
Gets a reference to the collection containing scalar data objects for results in
an ATVApp object.
Applies To ATVApp Object
Syntax object.ResultScalars
Data Type Collection
 Run Method
Launches the calculation engine to perform the calculation and returns a
status. It returns 0 if the calculation succeeded and a non-zero error code to
indicate an error if the calculation failed.
Applies To ATVApp Object
Syntax object.Run
Data Type Long
Remarks See the error descriptions for error code.
 Run2 Method
Launches the calculation engine to perform the calculation and returns a
status. It returns 0 if the calculation succeeded and a none-zero error code to
indicate an error if the calculation failed.
Applies To ATVApp Object
Syntax object.Run2([RunType] )
Data Type Long
Parameters
Optional. A Long value indicating the type of calculation
to be performed. If omitted, the method will act as
same as the Run method.
Note: C urrently only the Shell&TubeMech application
has different run types as shown below:
RunType Long
C alculations + C ost + Drawings
C alculations only
C alculations + C ost
C alculations + Drawings
 RunFinished Event
Gets fired when the calculation finished successfully.
Applies To ATVApp Object
Syntax Private Sub object_RunFinished
Example
The following example shows how to implement the RunFinished method to
catch the event when the calculation is done.
‘ Declarations
Private objBjac as BJACApp
Private WithEvents objAerotran as ATVApp ‘ you must use WithEvents
...
Private Sub MyMain( )
‘ Create a BJACApp object, and open an Aerotran problem file
...
‘ Get the Aerotran object, and run Aerotran
Set objAerotran = objBjac.Aerotran
objAerotran.Run
End Sub
Private Sub objAerotran_RunFinished()
‘ Add your code below. For example, retrieve some results
...
End Sub
 Scalars Property (Read-only)
Gets a reference to the collection containing scalar data objects for input in
an ATVApp object.
Applies To ATVApp Object
Syntax object.Scalars
Data Type Collection
 Show Method
Shows the Aspen EDR user interface.
Applies To BJACApp Object
Syntax object.Show
Remarks This statement is equivalent to object.Visible = False
 Text Property (Read-only)
Returns supplemental information to the Value property of the data object.
Applies To ATVArray Object, ATVScalar Object
Syntax object.Text([Index] ) for ATVArray object
object.Text for ATVScalar object
Parameters
Optional. A Long value representing the element
Index Long number in the array. If omitted, the first element is
assigned.

Data Type String

Remarks The Text property has no effect on the calculation, and is only used
to store extra information to help understanding of the Value property. For
example, for a data object representing a material, the Value property of the
data object will be the material number assigned by the Aspen EDR, and the
Text property will contains the description for the material.
Example
The example below prints the value and its text of an ATVScalar object on the
Debug Window:
Private Sub ShowApplicationType( Byval objHetran As ATVApp )
Dim objAppType As ATVScalar

‘ Get a reference to application type in hot side

Set objAppType = objHetran.Scalar(“ApplTypeHS”)

‘ Display the Value and Text in the Debug Window

Debug.Print objAppType.Value, objAppType.Text
End Sub
On the Debug Window, the results are:
1 Liquid, no phase change
 Uom Property
Returns or sets a String that represents the unit for a physical quantity data
object.
Applies To ATVArrayApp Object, ATVScalar Object
Syntax object.Uom [=NewUnitString] )
Data Type String
Remarks If an invalid unit string is supplied, the unit string remains
unchanged. Changing the unit string will not cause the value conversion.
 UomSet Property
Returns or sets a units of measure used in the object.
Applies To BJACApp Object, ATVApp Object
Syntax object.UomSet [=NewSetting%] )
Data Type Long
Remarks The UomSet property accepts the following constants:
Constant Value Description

ATV_UOMSET_US 1 US units set. Predefined in the program.

ATV_UOMSET_SI 2 SI units set. Predefined in the program

METRIC units set. Predefined in the

ATV_UOMSET_METRIC 3
program.

User units set. C ustomizable through the

ATV_UOMSET_SET1 4
UI

User units set. C ustomizable through the

ATV_UOMSET_SET2 5
UI

User units set. C ustomizable through the

ATV_UOMSET_SET3 6
UI

When a new setting is assigned to a BJACApp object, the new setting makes
no effect on the ATVApp objects that are created already. However, if a new
setting is assigned to an ATVApp object, the entire object, including the
contained data objects, or even the user interface window that represents the
object, will be changed accordingly.
 Value Property, Values Property
Returns or sets a value to the data object.
Applies To ATVArray Object, ATVScalar Object
Syntax object.Values([Index],[Uom] ) for ATVArray object
object.Value([Uom]) for ATVScalar object
Parameters
Optional. A Long value representing the element number
Index Long
in the array. If omitted, the first element is assigned.

Optional. A String value representing the units of

measure to be based or assigned if the data is a physical
quantity. If omitted the current units of measure will be
used.
Uom String
Note When the Uom parameter is used to returns a
value, the data will be converted according to the Uom.
However, if the Uom parameter is assigned the data
object, the value of the data object will not be converted.

Data Type Variant

Remarks The Value or Values property is a variant type variable. Depending

on the Category property, it uses different VB data types to represent the
data, and assigns different undefined constants when the data is Empty, as
shown in the following table:
VB Data Undefined
Data Category Note
Type Value

Used for physical quantities. It

returns 0 if the data is empty.
ATV_DATAC ATEGORY_PQ Single 0 You should use the IsEmpty
method to check to see if the
data is empty.

Used for StaticList. The Value

property represents the index of
an item in the list. The Text
property stores the item. You
ATV_DATAC ATEGORY_LIST Long -30000
must use a valid index number
when you assign a value to the
property.

User for numeric data except

physical quantities. You should
ATV_DATAC ATEGORY_NUM Single 0
use the IsEmpty method to check
the empty status.

ATV_DATAC ATEGORY_STR String “”

ATV_DATAC ATEGORY_BOOL Boolean False

The optional parameter Index is used only for an ATVArray object. It

represents the element number in the array object.
The optional parameter Uom is a string description for the units of measure,
for example, kg/s for mass flow rate. You can use the Uom parameter to
assign a new units of measure to the data, or returns a value based the
specified Uom parameter.
Example
Dim objHetran As ATVApp
Dim objArray As ATVArray
Dim objScalar As ATVScalar
Dim Buf As Single
...
‘ Get the reference to the hot side flow rate
Set objScalar = objHetran.Scalars(“FlRaHS”)

‘ Get the current value in kg/h no matter what units the data is
‘ actually using
Buf = objScalar.Value(“kg/h”)

‘ Assign the 10000 lb/h to the data

objScalar.Value(“lb/h”) = 10000.0 ‘ Now the data’s units is lb/h

‘ Get the reference to the specific heat for liquid cold side
Set objArray = objHetran.Arrays(“SpHtLiqCS“)

‘ Gets the value of the element #1 in the current units

Buf = objArray.Values(1)

‘ Assign a value to the element and change the units

objArray.Values(1,”kJ/(kg*K)”) = 0.2
...
 Visible Property
Returns or set a Boolean value that determines the Aspen EDR user interface
is visible or hidden.
Applies To BJACApp Object
Syntax object.Visible [=NewSetting]
Data Type Boolean
 Error Descriptions
Number Descriptions

-1 Input is incomplete

1000 An unknown error has occurred.

1001 Unknown security error occurred.

1002 C ouldn't detect security key on your system.

1003 C ouldn't detect HASP single-user security key on your system.

C ouldn't detect NetHASP key on your system or no active NetHASP server

1004
was found.

1005 License to run the program has expired.

1006 The program doesn't have enough BRUs to run.

1007 C ouldn't read security key.

1008 C ouldn't write to security key.

1009 The security key date or time has been changed.

1010 Failed to access NetHASP key.

1011 General security key error.

Failed to access Aspen License Manager(ASPLM) or no active ASPLM was

1012
found.

Number of stations that may run the application at the same time has been
1013
exceeded.

1014 No license was found to run the program.

1101 EXC EPTION_AC C ESS_VIOLATION has occurred.

1102 EXC EPTION_BREAKPOINT has occurred.

1103 EXC EPTION_DATATYPE_MISALIGNMENT has occurred.

1104 EXC EPTION_SINGLE_STEP has occurred.

1105 EXC EPTION_ARRAY_BOUNDS_EXC EEDED has occurred.

1106 EXC EPTION_FLT_DENORMAL_OPERAND has occurred.

1107 EXC EPTION_FLT_DIVIDE_BY_ZERO has occurred.

1108 EXC EPTION_FLT_INEXAC T_RESULT has occurred.

1109 EXC EPTION_FLT_INVALID_OPERATION has occurred.

1110 EXC EPTION_FLT_OVERFLOW has occurred.

1111 EXC EPTION_FLT_STAC K_C HEC K has occurred.

1112 EXC EPTION_FLT_UNDERFLOW has occurred.

1113 EXC EPTION_INT_DIVIDE_BY_ZERO has occurred.

1114 EXC EPTION_INT_OVERFLOW has occurred.

1115 EXC EPTION_PRIV_INSTRUC TION has occurred.

1116 EXC EPTION_NONC ONTINUABLE_EXC EPTION has occurred.

1200 The file <$> contains an unrecognized format.

1201 Error occurred while accessing a file.

1300 Failed to load Aspen Properties Plus DLL.

1301 Error occurred while executing Aspen Properties Plus.

1400 Fatal error in Aspen Plus / BJAC interface

 Process Data Cross-Checking Overview
Process data for each stream are checked at three levels:
· Self consistency at inlet and outlet
· Consistency between inlet and outlet flows and heat loads
· Heat balance between the streams
Before the Process data checking begins, you must specify inlet and outlet
pressures or default values are assumed. You can omit any other relevant
parameters, provided there is adequate information in the other process data
for it to be deduced. Assumptions are made in some cases to ensure the
Process data are complete, including estimated initial values for Simulation
calculations.
The key parameters involved in Process checking are:
· Parameters defining an inlet or outlet point:
– Pressure specific enthalpy
– Temperature
– Quality (vapor mass fraction)
· Parameters defining heat loads:
– Inlet and outlet specific enthalpies
– Mass flowrates
– Heat loads
· Parameters defining calculations:
– The Checking/Simulation (including the various Simulation options
of determining outlet conditions, or inlet conditions or heat loads)
– Whether the stream is hot or cold
– The flow configuration (co-current, countercurrent etc)
– The heat balance parameter for each stream, which identifies how
over-specification should be resolved
The Process Cross-checking is generalized to apply to a range of EDR
programs, not all of which offer all the options described. A basic Set Streams
procedure is repeated, making additional changes or corrections as necessary
until the Process data are fully defined or until an uncorrectable error is
detected.
 Process Data Cross-Checking Self-consistency
at Inlet and Outlet
Self-consistency of individual points involves cross-checking the pressure,
specific enthalpy, temperature, and quality at each point. In general, pressure
and one other parameter can define the other two. Specific enthalpy (not
available as a user input in some programs) is often deduced when a heat
balance assumption is used. If either a specified temperature or quality is
inconsistent with the value calculated from the specific enthalpy, the value is
corrected, and a message is generated.
If there is no specific enthalpy but a temperature has been specified, then the
temperature is used to determine the specific enthalpy and quality. If a
quality has also been specified, it is cross-checked against the calculated
value. If the program finds an inconsistency, then it adjusts either the quality
or the temperature, whichever causes the greater discrepancy, and a message
is generated.
If the substance is a pure component which is boiling or condensing
isothermally and the inlet or outlet point is at that temperature, you should
supply a quality (avoidable in some cases). If the specified inlet and outlet
temperatures are equal and quality information is missing, then the quality is
set to either 1 or 0 to indicate inlet/outlet at the dew or bubble point. If only
one of the inlet and outlet points is at the isothermal boiling/condensing
temperature and has no quality specified, then you might receive a warning,
but there will be no fatal error if the quality can be deduced from other
means.
If only pressure and quality are specified at a point and the quality is not 0 or
1, the program can determine the point. If the quality is 0 or 1, that is
initially supposed to imply anywhere in the liquid or vapor region, and the
program checks whether the inlet or outlet point can be determined from the
other end point, the mass flowrate, and the heat load (as input or determined
from a heat balance). If it is not, then the assumption is made that qualities 0
and 1, supplied in the absence of temperature or specific enthalpy
information, imply the bubble and dew point, respectively, at the relevant
pressure.
If, having made these assumptions for a Checking case, the Process data is
still incomplete, the program assumes that the outlet quality of a condensing
stream is 0, corresponding to complete condensation.
For a Simulation case, if the Process data is incomplete, then the program will
try to estimate the heat loads as the basis for completing the data.
See Also:
Process Data Cross-Checking Overview
 Process Data Cross-Checking Consistency of
Flows and Heat Loads
For each stream, the difference between the inlet and outlet specific
enthalpies, multiplied by the mass flowrate, must be equal to the stream heat
load. If only three of these four parameters are known, the fourth is
calculated. If all four are given (including the case where the heat load is
deduced from a heat balance), then the heat balance parameter is used to
determine which of the four should be revised to achieve internal consistency.
If fewer than three of the four parameters are known for any stream, even
after making assumptions and applying a heat balance or after setting an
estimated heat load for simulation, the program will issue a fatal error.
See Also:
Process Data Cross-Checking Overview
 Process Data Cross-Checking Heat Balance
between Streams
For a two stream exchanger program, such as Shell&Tube (Tasc+) or Plate
(Plate+), then the two streams must have the same heat load. Any specified
load applies to both streams. If the load is not specified for either stream but
can be deduced for one stream, this load is then used to predict the
performance of the other stream.
For the generalized N-stream exchanger case, the sum of the heat loads into
the system must be zero. For this sum, hot stream loads must be taken as
negative, and allowance must be made for any net external flow of heat into
the system. The net result, as for two stream exchangers, is that any one
unspecified heat load can be determined by a system heat balance.
For a two stream exchanger modeled by Shell&Tube, it is not necessary that
the streams have the same heat load in Checking calculations. The program
applies scaling factors internally to ensure that the specified flows and inlet
and outlet points are preserved. A heat load imbalance of up to 10%
(between an individual stream load and the mean load) can be handled.
Larger discrepancies are assumed to be unrealistic and create a fatal error.
Except for very small discrepancies (below 1%), a warning message is
produced when loads do not balance.
For Simulation calculations with Shell&Tube, a heat balance is always
assumed. Heat loads are scaled to the mean value before the calculation
begins, with a corresponding change being made in the outlet point, inlet
point, or flowrate, depending on which is being predicted in the Simulation.
For a two-stream exchanger with specified inlet conditions and flowrates, it is
possible to determine a maximum possible heat load and also to set an
estimated heat load. Two maximum loads are determined:
· The absolute maximum which would apply to pure countercurrent flow.
· The maximum “no cross” heat load at which stream temperature ranges
do not overlap. This is the maximum for pure co-current flows, but is useful in
estimating the maximum load and estimated load for other circumstances.
For flow configurations more complex than pure co- or counter-current flow
(for example crossflow, or multi-pass exchanger, or multiple multi-pass shells
in series), a maximum heat load for the configuration is estimated.
For Checking calculations, a heat load above the maximum possible value
constitutes an error. A heat load above a maximum estimated for a specific
configuration generates only a warning to allow for the case when the
estimate is incorrect. However, cases close to or above the maximum value
might be impractical and lead to a Checking calculation that fails to find a
result.
For Simulation cases, initial heat loads above 99% of the maximum practical
value are scaled back to this 99% limit before the calculation begins. A
warning is issued if the input data are such that revision has been necessary,
to achieve a heat balance or to conform to limiting heat loads. Messages also
appear if input temperatures or qualities are inconsistent with the revised
heat load.
When no initial value of heat load is available in a Simulation case for a two-
stream exchanger, an estimated initial value is set to 80% of the maximum
practical vale for the particular configuration.
See Also:
Process Data Cross-Checking Overview
 Common Bare Tube Diameters and Gauges
Carbon Steel
Copper and Aluminum &
O.D. Other Alloys Wall Thickness
Copper Alloys Aluminum
Alloys

in mm BWG BWG BWG in mm

27 - 27 0.016 0.406

1/4 6.5 24 - 24 0.018 0.457

22 - 22 0.022 0.559

22 - 22 0.022 0.559

3/8 9.5 20 - 20 0.035 0.889

18 - 18 0.049 1.24

1/2 12.7 20 - 20 0.035 0.889

18 - 18 0.049 1.24

20 - 20 0.035 0.889

5/8 15.9 18 18 18 0.049 1.24

16 16 16 0.065 1.65

- 14 - 0.083 2.11

20 - - 0.035 0.889

18 - 18 0.049 1.24

3/4 19.1 16 16 16 0.065 1.65

- 14 14 0.083 2.11

- 12 - 0.109 2.77

18 - - 0.049 1.24

16 - 16 0.065 1.65

7/8 22.2 14 14 14 0.083 2.11

12 12 12 0.109 2.77

- 10 - 0.134 3.40

18 - - 0.049 1.24

1 25.4 16 - 16 0.065 1.65

14 14 14 0.083 2.11

- 12 12 0.109 2.77
 16 - - 0.065 1.65

1-1/4 31.8 14 14 14 0.083 2.11

- 12 12 0.109 2.77

16 - - 0.065 1.65

1-1/2 38.1 14 14 14 0.083 2.11

- 12 12 0.109 2.77

2 50.8 14 14 14 0.083 2.11

12 12 12 0.109 2.77
 Tube Low Fin Information
Standard fin outside diameters
in: 1.5 2.0 2.5 3.0 3.5
mm: 38 50 63 76 89
Program Default: Tube Outside Diameter + 0.75 in or 19.05 mm

Standard fin thickness

integral or extruded: 0.012-0.025 in or 0.3-0.7 mm
welded or wrapped: 0.025-0.165 in or 0.6-4 mm
in: 0.031 0.036 0.049 0.059
mm: 0.8 0.9 1.2 1.5
Program Defaults:
0.23 in or 0.58 mm for tube O.D. less than 2 in or 50.8
0.36 in or 0.91 mm for tube O.D. greater than 2 in or 50.8 mm
 Enhanced Surfaces Standard Sizes
The following list contains the standard available tube sizes that are available
for the indicated enhance surfaces.

Manufacture Type Tube OD, in Wall Thk, in

Wolverine TURBO B MHT

1 3/4" OD .051" WALL

2 3/4" OD .054" WALL

3 3/4" OD .059" WALL

4 3/4" OD .065" WALL

7 1" OD .053" WALL

Wolverine TURBO B LPD

5 3/4" OD .051" WALL

6 3/4" OD .057" WALL

Wolverine TURBO C MHT

1 1" OD .052" WALL

2 3/4" OD .051" WALL

3 3/4" OD .054" WALL

4 3/4" OD .058" WALL

Wolverine TURBO C LPD

5 3/4" OD .051" WALL

Wolverine TURBO BII

1 3/4" OD .049" WALL

2 3/4" OD .051" WALL

3 3/4" OD .058" WALL

Wolverine TURBO CII

1 3/4" OD .047" WALL

2 3/4" OD .050" WALL

3 3/4" OD .056" WALL

Wolverine KORODENSE MHT

Wolverine KORODENSE LPD

1 5/8" OD .020" WALL

2 5/8" OD .025" WALL

3 5/8" OD .032" WALL

4 5/8" OD .035" WALL

5 5/8" OD .042" WALL

6 5/8" OD .049" WALL

7 5/8" OD .065" WALL

8 3/4" OD .020" WALL

9 3/4" OD .025" WALL

10 3/4" OD .032" WALL

11 3/4" OD .035" WALL

12 3/4" OD .042" WALL

13 3/4" OD .049" WALL

14 3/4" OD .065" WALL

15 7/8" OD .020" WALL

16 7/8" OD .025" WALL

17 7/8" OD .032" WALL

18 7/8" OD .035" WALL

19 7/8" OD .042" WALL

20 7/8" OD .049" WALL

21 7/8" OD .065" WALL

22 1" OD .020" WALL

23 1" OD .025" WALL

24 1" OD .032" WALL

25 1" OD .035" WALL

26 1" OD .042" WALL

27 1" OD .049" WALL

28 1" OD .065" WALL

29 1-1/8" OD .025" WALL

30 1-1/8" OD .032" WALL

31 1-1/8" OD .035" WALL

32 1-1/8" OD .042" WALL

33 1-1/8" OD .049" WALL

34 1-1/8" OD .065" WALL

35 1-1/4" OD .025" WALL

36 1-1/4" OD .032" WALL

37 1-1/4" OD .035" WALL

38 1-1/4" OD .042" WALL

39 1-1/4" OD .049" WALL

40 1-1/4" OD .065" WALL

 ANSI Pipe Dimensions
ANSI Pipe Dimensions Dimensions: in
Nom
0.75 1.0 1.25 1.5 2.0 2.5 3.0 3.5 4.0 5.0
OD
Actual
1.050 1.315 1.660 1.900 2.375 2.875 3.500 4.000 4.500 5.563
OD
Sch 5S 0.065 0.065 0.065 0.065 0.065 0.083 0.083 0.083 0.083 0.109
Sch
0.083 0.109 0.109 0.109 0.109 0.120 0.120 0.120 0.120 0.134
10S
Sch 10 --- --- --- --- --- --- --- --- --- ---
Sch 20 --- --- --- --- --- --- --- --- --- ---
Sch 30 --- --- --- --- --- --- --- --- --- ---
Std 0.113 0.133 0.140 0.145 0.154 0.203 0.216 0.226 0.237 0.258
Sch 40 0.11 0.133 0.140 0.145 0.154 0.203 0.216 0.226 0.237 0.258
Sch 60 --- --- --- --- --- --- --- --- --- ---
Ext Str 0.154 0.179 0.191 0.200 0.218 0.276 0.300 0.318 0.337 0.375
Sch 80 0.154 0.179 0.191 0.200 0.218 0.276 0.300 0.318 0.337 0.375
Sch
--- --- --- --- --- --- --- --- --- ---
100
Sch
--- --- --- --- --- --- --- --- 0.438 0.500
120
Sch
--- --- --- --- --- --- --- --- --- ---
140
Sch
0.219 0.250 0.250 0.281 0.344 0.375 0.438 --- 0.531 0.625
160
XX Str 0.308 0.358 0.382 0.400 0.436 0.552 0.600 --- 0.750 0.864

ANSI Pipe Dimensions Dimensions: in

Nom
6 8 10 12 14 16 18 20 22 24
OD
Actual
6.625 8.625 10.75 12.75 14.0 16.0 18.0 20.0 22.0 24.0
OD
Sch 5S 0.109 0.109 0.134 0.156 0.156 0.165 0.165 0.188 0.188 0.218
Sch
0.134 0.148 0.165 0.180 0.188 0.188 0.188 0.218 0.218 0.250
10S
Sch 10 --- --- --- --- 0.250 0.250 0.250 0.250 0.250 0.250
Sch 20 --- 0.250 0.250 0.250 0.312 0.312 0.312 0.375 0.375 0.375
Sch 30 --- 0.277 0.307 0.330 0.375 0.375 0.438 0.500 0.500 0.562
Std 0.280 0.322 0.365 0.375 0.375 0.375 0.375 0.375 0.375 0.375
Sch 40 0.280 0.322 0.365 0.406 0.438 0.500 0.562 0.594 --- 0.688
Sch 60 --- 0.406 0.500 0.562 0.594 0.656 0.750 0.812 0.875 0.969
Ext Str 0.432 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500 0.500
Sch 80 0.432 0.500 0.594 0.688 0.750 0.844 0.938 1.031 1.125 1.218
Sch
100 --- 0.594 0.719 0.844 0.938 1.031 1.156 1.281 1.375 1.531
Sch
0.562 0.719 0.844 1.000 1.094 1.219 1.375 1.500 1.625 1.812
120
Sch
--- 0.812 1.000 1.125 1.250 1.438 1.562 1.750 1.875 2.062
140
Sch
0.719 0.906 1.125 1.312 1.406 1.594 1.781 1.969 2.125 2.344
160
XX Str 0.864 0.875 1.000 1.000 --- --- --- --- --- ---

ANSI Pipe Dimensions Dimensions: mm

Nom
19 25 32 38 51 64 76 89 102 127
OD
Actual
26.6 33.4 42.2 48.3 60.3 73.0 88.9 101.6 114.3 141.3
OD
Sch
1.6 1.6 1.6 1.6 1.6 2.1 2.1 2.1 2.1 2.7
5S
Sch
2.1 2.7 2.7 2.7 2.7 3.0 3.0 3.0 3.0 3.4
10S
Sch
--- --- --- --- --- --- --- --- --- ---
10
Sch
--- --- --- --- --- --- --- --- --- ---
20
Sch
--- --- --- --- --- --- --- --- --- ---
30
St --- 3.4 3.6 3.7 3.9 5.2 5.5 5.7 6.0 6.6
Sch
2.8 3.4 3.6 3.7 3.9 5.2 5.5 5.7 6.0 6.6
40
Sch
--- --- --- --- --- --- --- --- --- ---
60
Ext
3.9 4.5 4.9 5.1 5.5 7.0 7.6 8.1 8.6 9.5
Str
Sch
3.9 4.5 4.9 5.1 5.5 7.0 7.6 8.1 8.6 9.5
80
Sch
--- --- --- --- --- --- --- --- --- ---
100
Sch
--- --- --- --- --- --- --- --- 11.1 12.7
120
Sch
--- --- --- --- --- --- --- --- --- ---
140
Sch
5.5 6.4 6.4 7.1 8.7 9.5 11.1 --- 13.5 15.9
160
XX
7.8 9.1 9.7 10.2 11.1 14.0 15.2 16.2 17.1 19.1
Str

ANSI Pipe Dimensions Dimensions: mm

Nom
152 203 254 305 356 406 457 508 559 610
OD
Actual
168.3 219.1 273.1 323.9 355.6 406.4 457.2 508.0 558.8 609.6
OD
Sch
2.7 2.7 3.4 4.0 4.0 4.0 4.0 4.8 4.8 5.5
5S
Sch
3.4 3.7 4.1 4.5 4.8 4.8 4.8 5.5 5.5 6.3
10S
Sch
--- --- --- --- 6.3 6.3 6.3 6.3 6.3 6.3
10
Sch
--- --- --- --- 7.9 7.9 7.9 9.5 9.5 9.5
20
Sch
--- 7.0 7.8 8.4 9.5 9.5 11.1 12.7 12.7 14.3
30
Std 7.1 8.2 9.3 9.5 9.5 9.5 9.5 9.5 9.5 9.5
Sch
7.1 8.2 9.3 10.3 11.1 12.7 14.3 15.1 --- 17.5
40
Sch
--- 10.3 12.7 14.3 15.1 16.7 19.1 20.6 22.2 24.6
60
Ext
11.0 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7 12.7
Str
Sch
11.0 12.7 15.1 17.5 19.1 21.4 23.8 26.2 28.6 30.9
80
Sch
--- 15.1 18.3 21.4 23.8 26.2 29.4 32.5 34.9 38.9
100
Sch
14.3 18.3 21.4 25.4 27.8 31.0 34.9 38.1 --- 46.0
120
Sch
--- 20.6 25.4 28.6 31.8 36.5 39.7 44.5 --- 52.4
140
Sch
18.3 23.0 28.6 33.3 35.7 40.5 45.2 50.0 --- 59.5
160
XX Str 21.9 22.2 25.4 25.4 --- --- --- --- --- ---
 DIN / ISO 4200 Pipe Dimensions

DIN / ISO 4200 Pipe Dimensions Dimensions: mm

Nom
20 25 32 40 50 65 80 100 125 150
OD
Actual
26.9 33.7 42.4 48.3 60.3 76.1 88.9 114.3 139.7 168.3
OD
Row A 1.6 1.6 1.6 1.6 1.6 1.6 2.0 2.0 2.0 2.0
Row B --- 2.0 2.0 2.0 2.0 2.3 2.3 2.3 2.3 2.3
Row C --- --- --- --- 2.3 2.6 2.9 2.9 3.2 3.2
Row D 1.8 2.0 2.3 2.3 2.3 2.6 2.9 3.2 3.6 4.0
Row E 2.0 2.3 2.6 2.9 2.9 2.9 3.2 3.6 4.0 4.5
Row F 3.2 3.2 3.6 3.6 4.0 5.0 5.6 6.3 6.3 7.1
Row G 4.0 4.5 5.0 5.0 5.6 7.1 8.0 8.8 10 11

DIN / ISO 4200 Pipe Dimensions Dimensions: mm

Nom
200 250 300 350 400 450 500 600 700 800
OD
Actual
219.1 273 323.9 355.6 406.4 457 508 610 711 813
OD
Row A 2.0 2.0 2.6 2.6 2.6 3.2 3.2 3.2 4.0 4.0
Row B 2.6 3.6 4.0 4.0 4.0 4.0 5.0 5.6 6.3 7.1
Row C 3.6 4.0 4.5 5.0 5.0 5.0 5.6 6.3 7.1 8.0
Row D 4.5 5.0 5.6 5.6 6.3 6.3 6.3 6.3 7.1 8.0
Row E 6.3 6.3 7.1 8.0 8.8 10 11 12.5 14.2 16
Row F 8.0 10 10 11 12.5 14.2 16 17.5 20 22.2
Row G 12.5 14.2 16 17.5 20 22.2 25 30 32 36
 Standard Nozzle Flange Ratings
ANSI 50 300 400 600 900 1500 2500

ISO 10 16 20 25 40 50 100

DIN 10 16 25 40 63 100 160 250 320 400

 Generic Materials

Abbrev Material

CS Carbon Steel
C½Mo Low Alloy Steel C½Mo
½Cr½Mo Low Alloy Steel ½Cr½Mo
Cr½Mo Low Alloy Steel Cr½Mo
1¼Cr½Mo Low Alloy Steel 1¼Cr½Mo
SS 304 High Alloy Steel Grade 304

High Alloy Steel Grade

SS 304L
304L

High Alloy Steel Grade

SS 316L
316L

High Alloy Steel Grade

SS 310S
310S

SS 347 High Alloy Steel Grade 347

High Alloy Steel Grade

SS 310S
310S

High Alloy Steel Grade XM-

SS XM-27
27

SS 410 High Alloy Steel Grade 410

Abbrev Material

NI 200 Nickel Alloy 200

Nickel Low Carbon Alloy

NI 201
201

Monel Nickel Alloy 400 (Monel)

Inconel Nickel Alloy 600 (Inconel)

NI 800 Nickel Alloy 800

Nickel Alloy 825 (Incoloy

NI 825
825)

Hast. B Nickel Alloy B (Hastelloy B)

Hast. C Nickel Alloy C (Hastelloy C)

Hast. G Nickel Alloy G (Hastelloy G)

Nickel Alloy 20 Cb
NI 20
(Carpenter 20)

Titanium Titanium
Cu-Ni Copper-Nickel 70/30 Alloy
70/30 CDA 715

Cu-Ni Copper-Nickel 90/10 Alloy

90/10 CDA 706

Copper-Silicon Alloy CDA

Cu-Si
655

NavBrass Naval Brass Alloy 464

Aluminum-Bronze Alloy
AlBronze
630

AlBrass Aluminum-Brass Alloy 687

Admiralty Admiralty Alloy 443

Tantalum Tantalum

Zirconium Zirconium
 Gaskets - hot side
Specify one of the following generic materials for the gaskets:
compressed fiber
flat metal jacketed fiber
solid flat metal
solid teflon
graphite
spiral wound
ring joint
self-energized
elastomers
 Gaskets - cold side
Specify one on the following generic gasket materials:
compressed fiber
flat metal jacketed fiber
solid flat metal
solid teflon
graphite
spiral wound
ring joint
self-energized elastomers
 Corrosion Table
The following table is provided as a quick reference for acceptable materials of
construction. The corrosion ratings are at a single temperature (usually 20 C)
and a single concentration. A final decision on material selection should be
based on operating temperature, actual concentration and galvanic action.

A = Excellent B = Good C = Fair

D = Not E=
I = Ignites
suitable Explosive

- = Information not available

These are the material abbreviations used in the table:

CS Carbon steel

Cu Copper

Admi Admiralty

Copper
CuSi
silicon

Cupro-nickel
CN90
90-10

Cupro-nickel
CN70
70-30

Stainless
SS304
steel 304

Stainless
SS316
steel 316

Ni Nickel

Monel Monel

Inco Inconel

Hast Hastelloy

Ti Titanium

Zr Zirconium

Ta Tantalum

Corrosion CN CN SS SS Mo In
CS Cu Admi CuSi Ni Hast Ti Zr Ta
Table 90 70 304 316 nel co
Acetaldehyde A E E E E E A A A A A A B - A

Acetic acid D D D D C C A A D A B A A A A

Acetic
D B C B B B B B B B B A A A B
anhydride

Acetone A A A A A A A A B A A B A - A

Acetylene A E E E E E A A A A A A A - A

Aluminum
D D D D D D D D C B D A A A A
chloride

Aluminum
B B B B B B B B B B B B - - B
hydroxide

Ammonia
A A A A A A A A B A B B A - A
(anhydrous)

Ammonium
D D D D D D B B B B B B A A A
chloride

Ammonium
C C C C C C C C B A B B A A A
sulfate

Ammonium
D B B B B B C C D D D - A - A
sulfite

Corrosion CN CN SS SS Mo In
CS Cu Admi CuSi Ni Hast Ti Zr Ta
Table 90 70 304 316 nel co

Amyl acetate B A A B A A A A A A A B A - A

Aniline A D D D D D A A B B B B A - A

Aroclor B A A A A A B B A A A A A - A`

Barium
B B C B B B B B B B B B A A A
chloride

Benzaldehyde B B B B B B B B B B B A A - A

Benzene A A A A A A B B B B B B A - A

Benzoic acid D B B B B B B B B B B B A - A

Boric acid D B B B B B A A B B B A A - A

Butadiene A A A A A A A A A A A A A - A

Butane A A A A A A A A A A A A A - A

Butanol A A A A A A A A A A A A A - A

Butyl acetate A B B B B B B B A B A B A - A

Corrosion CN CN SS SS Mo In
CS Cu Admi CuSi Ni Hast Ti Zr Ta
Table 90 70 304 316 nel co

Butyl chloride A A A A A A A A A A A A A - A
Calcium chloride B B C B B B C B A A A B A A A

Calcium
B B B B B B B B B B B B A - A
hydroxide

Carbon
C C C C C C A A A A A A A - A
dioxide(wet)

Carbon
B B B B B B B B A A A B A A A
tetrachloride

Carbonic acid C C C C C C B B B C A A A - A

Chlorine gas
B B B B B B B B B B A B I A A
(dry)

Chloroform
B B B B B B B B A A B B A A A
(dry)

Chromic acid D D D D D D C B D D B B B A A

Citric acid D C C C C C C B B B A C A A A

Creosote B B B B B B B B B B B B A - A

Dibutylphthalate A A A A A A B B B B B B A - A

CN CN SS SS Mo In
Corrosion Table CS Cu Admi CuSi Ni Hast Ti Zr Ta
90 70 304 316 nel co

Dichlorobenzene B B B B B B B B B B B B B - A

Dichlorofluorometh A A A A A A A B B B B A A - A

Diethanolamine A B B B B B A A A A A A A - A

Diethyl etheride B B B B B B B B B B B B A - A

Diethylene glycol A B B B B B A A B B B B A - A

Diphenyl B B B B B B B B B B B B A - A

Diphenyl oxide B B B B B B B B B B B B A - A

Ethane A A A A A A A A A A A A A - A

Ethanolamine B B B B B B A B B B B B B - A

Ether B B B B B B B B B B B B A - A

Ethyl acetate (dry) B B B B B B B B B B B B A - A

Ethyl alcohol B B B B B B B B B B B A A A A

Corrosion CN CN SS SS Mo In
CS Cu Admi CuSi Ni Hast Ti Zr Ta
Table 90 70 304 316 nel co

Ethyl ether B B B B B B B B B B B B A - A

Ethylene A A A A A A A A A A A A A - A
Ethylene
glycol B B B B B B B B B B B B A - A

Fatty acids D D D D D D D A B C B A B - A

Ferric chloride D D D D D D D D D D D B A D A

Ferric sulfate D D D D D D B B D D D A A - A

Ferrous
D B B B B B B B D D D B A - A
sulfate

Formaldehyde D B B B B B B B B B B B B - A

Furfural B B B B B B B B B B B B A - A

Glycerine A A A A A A A A A A A A A - A

Hexane A A A A A A A A A A A A A - A

Hydrochloric
D D D D D D D D D D D B D D A
acid

Corrosion CN CN SS SS Mo In
CS Cu Admi CuSi Ni Hast Ti Zr Ta
Table 90 70 304 316 nel co

Hydrofluoric
D C D D D C D D D C D A D D D
acid

Iodine D D D D D D D D D D D B D - A

Isopropanol A B B B B B B B B B B B A - A

Lactic acid D B C B B B B A B C A A A A A

Linseed oil A B B B B B A A B B B B A - A

Lithium
B B B B B B B A A A A A - - A
chloride

Lithium
B B B B B B B B B B B B - - A
hydroxide

Magnesium
B B C B B B B B A B A A A A A
chloride

Magnesium
B B B B B B B B B B B B A - B
hydroxide

Magnesium
B B B B B B A A B B B A A A A
sulfate

Methane A A A A A A A A A A A A A A A

Methallyamine C B B B B B B B B C B B B - A

CN CN SS SS Mo In
Corrosion Table CS Cu Admi CuSi Ni Hast Ti Zr Ta
90 70 304 316 nel co

Methyl alcohol B B B B B B B B B A B A A A A
Methyl chloride A A A A A A A A B B B B A - A
(dry)

Methylene chloride B B B B B B B B B B B B B - A

Monochlorobenzene B B B B B B B B A A A B B - A

M.dichl.difl.mehane A A A A A A A A A A A A A - A

Monoethanolamine B B B B B B B B B B B - - - A

Naptha A B B B B B B B B B B B B - A

Napthalene A B B B B B A A A A A B B - A

Nickel chloride D B B B B B B B D B D A A A A

Nickel sulfate D B B B B B B B B B B B B A A

Nitric acid D D D D D D B B D D D D A B A

Nitrous acid D D D D D D B B D D D - - - A

CN CN SS SS Mo In
Corrosion Table CS Cu Admi CuSi Ni Hast Ti Zr Ta
90 70 304 316 nel co

Oleic acid B B B B B B B B A A A B B B B

Oxalic acid D B B B B B B B C B B B D B A

Perchloric acid
D D D D D D B B D D D - - - A
(dry)

Perchloroethylene A B B B B B B B A A A - A - A

Phenoldehyde B B B B B B B B B A B A A - A

Phosphoric acid D D D D D D B B D D B A C D B

Phthalic
B B B B B B B B B B B B - - A
anhydride

Potassium
B B B B B A B B B B B B A - A
bicarbonate

Potassium
B B B B B B B B B B B B A - A
carbonate

Propylene glycol B B B B B B B B B B B B A - A

Pyridine A B B B B B B B B B B B B - A

Refrigerant 12 A A A A A A A B B B B A A - A

Corrosion CN CN SS SS Mo In
CS Cu Admi CuSi Ni Hast Ti Zr Ta
Table 90 70 304 316 nel co

Refrigerant 22 A A A A A A A A A A A A A - A

Seawater C B A B A A A A B A B B A A A
Silver chloride D D D D D D D D D D C B B - A

Silver nitrate D D D D D D B B D D B B A A A

Sodium acetate D B B B B B B B B B B B B - A

Sodium
D D D D D D D D A B B B B B D
hydroxide

Sodium nitrate B B B B B B A A B B A B A - A

Sodium sulfate B B B B B B B A B B B B A - A

Sulfur
B B B B B B B B B B B B A - A
dioxide(dry)

Sulfuric acid D D D D D D D D D D D B D A A

Toluene A A A A A A A A A A A A A A A

Trichlorethylene B B B B B B B B A A B A A A A

Turpentine B B B B B B B B B B B B B - A

Vinyl chloride
A B C B B B B A A A A A A - A
(dry)

Water (fresh) C A A A A A A A A A A A A A A

Water (sea) C B A B A A A A B A B B A A A

Xylene B A A A A A A A A A A A A A A

Zinc chloride D D D D D D B B B A D B A A A

Zinc sulfate D B B B B B B A B B A B A - A
 Refrigerant Cross Referencing Table

Boiling Boiling
R Chemical Name Formula Mass
Point C Point F

tetrachloromethane (carbon
10 C C l4 153.8 77 171
tetrachloride)

11 trichlorofluoromethane C C l3F 137.4 24 75

12 dichlorodifluoromethane C C l2F2 120.9 -30 -22

12B1 bromochlorodifluoromethane C BrC lF2 165.4 -4 25

12B2 dibromodifluoromethane C Br2F2 209.8 25 77

13 chlorotrifluoromethane C C lF3 104.5 -81 -115

13B1 bromotrifluoromethane C BrF3 148.9 -58 -72

tetrafluoromethane (carbon
14 C F4 88.0 -128 -198
tetrafluoride)

20 trichloromethane (chloroform) C HC l3 119.4 61 142

21 dichlorofluoromethane C HC l2F 102.9 9 48

22 chlorodifluoromethane C HC lF2 86.5 -41 -41

22B1 bromodifluoromethae C HBrF2 130.9 -15 5

23 trifluoromethane C HF3 70.0 -82 -116

30 dichloromethane (methylene chloride) C H2C l2 84.9 40 104

31 cholrofluoromethane C H2C lF 68.5 -9 16

32 difluoromethane (methylene fluoride) C H2F2 52.0 -52 -62

40 chloromethane (methyl chloride) C H3C l 50.5 -24 -12

41 fluoromethane (methyl fluoride) C H3F 34.0 -78 -108

50 methane C H4 16.0 -161 -259

110 hexachloroethane C C ll3C C l3 236.8 185 365

111 pentachlorofluoroethane C C l3C C l2F 220.3 135 275

112 1,1,2,2-tetrachloro-1,2-difluoroethane C C l2FC C l2F 203.8 93 199

112a 1.1.1.2-tetrachloro-2,2-difluoroethane C C l3C C lF2 203.8 91 196

113 1,1,2-trichloro-1,2,2-trifluoroethane C C l2FC C lF2 187.4 48 118

113a 1,1,1-trichloro-2,2,2-trifluoroethane C C l3C F3 187.4 46 115

114 1,2-dichloro-1,1,2,2-tetrafluoroethane C C lF2C C lF2 170.9 4 38

114a 1,1-dichloro-1,2,2,2-tetrafluoroethane C C l2FC F3 170.9 3 37

114B2 1,2-dibromo 1.1.2.2-tetrafluoroethane C BrF2C BrF2 259.9 47 117

115 chloropentafluoroethane C C lF2C F3 154.5 -39 -38

116 hexafluoroethane C F3C F3 138.0 -78 -109

120 pentachloroethane C HC l2C C l3 202.3 162 324

123 2,2-dichloro-1,1,1-trifluoroethane C HC l2C F3 153.0 27 81

123a 1,2-dichloro-1,1,2-trifluoroethane C HC lFC C lF2 153.0 28 82

124 2-chloro-1,1,1,2-tetrafluorethane C HC lFC F3 136.5 -12 10

124a 1-chloro-1,1,2,2-tetrafluoroethane C C lF2C HF2 136.5 -10 14

125 pentafluoroethane C HF2C F3 120.0 -49 -56

133a 2-chloro-1,1,1-trifluoroethane C H2C lC F3 118.5 6 43

134a 1,1,1,2-tetrafluoroethane C F3C H2F 102.0 -26 -15

1,1,1-trichloroethane (methyl
140a C C l3C H3 133.4 74 165
chloroform)

141b 1,1-dichloro-1-fluoroethane C C l2FC H3 117.0 32 90

142b 1-chloro-1,1-difluoroethane C C lF2C H3 100.5 -10 14

143a 1,1,1-trifluoroethane C F3C H3 84.0 -47 -53

150a 1,1-dichloroethane C HC l2C H3 99.0 57 135

152a 1,1-difluoroethane C HF2C H3 66.0 -25 -13

160 chloroethane (ethyl chloride) C H3C H2C l 64.5 12 54

170 ethane C H3C H3 30.0 -89 -128

1,3-dichloro-1,1,2,2,3,3-
216ca C C lF2C F2C C lF2 221.0 36 97
hexafluoropropane

218 octafluoroproprane C F3C F2C F3 118.0 -37 -35

245cb 1,1,1,2,2-pentafluoropropane C F3C F2C H3 134.0 -18 0

290 propane C H3C H2C H3 44.0 -42 -44

1,2-dichloro-1,2,3,3,4,4-
C 316 C 4C l2F6 233.0 60 100
hexafluorocyclobutane

C 317 chloroheptafluorocyclobutane C 4C lF7 216.5 26 79

C 318 octafluorocyclobutane C 4F8 200.0 -6 21

600 butane C H3C H2C H2C H3 58.1 0 31

600a 2-methyl propane (isobutane) C H(C H3)3 58.1 -12 11

610 ethyl ether C 2H5OC 2H5 74.1 35 94

611 methyl formate HC OOC H3 60.0 32 89

630 methyl amine C H3NH2 31.1 -7 20

631 ethyl amine C 2H5NH2 45.1 17 62

702 hydrogen H2 2.0 -253 -423

704 helium He 4.0 -269 -452

717 ammonia NH3 17.0 -33 28

718 water H2O 18.0 100 212

720 neon Ne 20.2 -246 -411

728 nitrogen N2 28.1 -196 -320

732 oxygen O2 32.0 -183 -297

740 argon Ar 39.9 -186 -303

744 carbon dioxide C O2 44.0 -78 -109

744A nitrous oxide N2O 44.0 -90 -129

764 sulfur dioxide SO2 64.1 -10 14

1112a 1,1-dichloro-2,2-difluoroethene C C l2=C F2 133.0 19 66

1113 1-chloro-1,2,2-trifluoroethene C C lF=C F2 116.5 -28 -18

1114 tetrafluoroethene C F2=C F2 100.0 -76 -105

1120 trichloroethene C HC l-C C l2 131.4 87 189

1130 1,2-dichloroethene (trans) C HC l=C HC l 96.9 48 118

1132a 1,1-difluoroethene (vinylidene fluoride) C F2=C H2 64.0 -82 -116

1140 1-chloroethene (vinyl chloride) C HC l-C H2 62.5 -114 7

1141 1-fluoroethen (vinyl fluoride) C HF=C H2 46.0 -72 -98

1150 ethene (ethylene) C H2=C H2 28.1 -104 -155

1270 propene (propylene) C H3C H=C H2 42.1 -48 -54

Zeotropes

Boiling Boiling
R Chemical Name Formula Mass
Point C Point F

400 R-12/114 (percent not specified)

401A R-22/152a/124 (53/13/34)

401B R-22/152a/124 (61/11/28)

410C R-22/152a/124 (33/15/52)

402A R-125/290/22 (60/2/38)

402B R-125/290/22 (38/2/60)

403A R-290/22/218 (5/75/20)

403B R-290/22/218 (5/56/39)

404A R-125/143a/134a (44/52/4)

405A R-22/152a/142b/C 318 (45/7/5.5/42.5)

406A R-22/600a/142b (55/4/41)

407A R-32/125/134a (20/40/40)

407B R-32/125/134a (10/70/20)

407C R-32/125/134a (23/25/52)

407D R-32/125/134a (15/5/70)

408A R-125/143a/22 (7/46/47)

409A R-22/124/142b (60/25/15)

409B R-22/124/142b (65/25/10)

410A R-32/125 (50/50)

410B R-32/125 (45/55)

411A R-1270/22/152a (1.5/87.5/11.0)

411B R-1270/22/152a (3/94/3)

412A R-22/218/142b (70/5/25)

Azeotropes

Boiling Boiling
R Chemical Name Formula Mass
Point C Point F

500 R-12/152a (73.8/26.2) -33 -27

501 R-22/12 (75/25) -41 -42

502 R-22/115 (48.8/51.2) -45 -49

503 R-023/13 (40.1/59.9) -88 -126

504 R-32/115 (48.2/51.8) -57 -71

505 R-12/31 (78/22) -30 -22

506 R-31/114 (55.1/44.9) -12 10

507A R-125/143a (50/50) -46 -52

508A R-23/116 (39/61) -86 -122

508B R-23/116 (49/54) -88 -126

509A R-22/218 (44/56) -47 -53

 ASME Code Case 2278
Alternative Method for Calculating Maximum Allowable Stresses Based on a
Factor of 3.5 on Tensile Strength Section II and Section VIII Div. 1.
Important items are:
These materials are the same as previously used. No chemical specifications
have been changed.
Materials are limited to those listed in the tables in ASME-VIII Div.1 (for
example, UCS-23).
The maximum permitted temperature for these materials are less than the
original listings.
Only materials with both tensile strength and yield strength tables can be
used (ASME Section II, Part D - if the materials are not listed on tables U and
Y-1, they can not be used per code case 2278).
New figure provided for the calculation of the reduction in minimum design
metal temperature without impact testing.
The allowable stress values are calculated from the tensile strength and the
yield strength.
The application of this case is not recommended for gasketed joints or other
applications where slight distortion can cause leakage or malfunction.
The hydrostatic test factor is reduced from 1.5 to 1.3.
All other code requirements apply (external pressure charts, etc.).
When using code case 2278, no reference is made to this case when the
program lists materials. It is recommended that you note the use of code case
in you file headings description. You select the usage of code case 2278 as an
input in the program options section.
 ASME Code Case 2290
Alternative Maximum Allowable Stresses Based on a Factor of 3.5 on Tensile
Strength Section I. Part D and Section VIII Division 1.
Important items are:
These materials are the same as previously used. No chemical specifications
have been changed.
The alternative maximum allowable stresses are listed in Table 1 of code case
2290 (same format as Section II, Part D materials).
New figure provided for the calculation of the reduction in minimum design
metal temperature without impact testing.
The application of this case is not recommended for gasketed joints or other
applications where slight distortion can cause leakage or malfunction.
The hydrostatic test factor is reduced from 1.5 to 1.3.
All other code requirements apply (external pressure charts, etc.).
When using code case 2290, the program will access a new database in which
all materials end with the characters '2290'. Therefore, the user and inspector
will know what materials fall within this code case. This new database will be
listed in the user's interface as 'ASME-2290'. All materials in the new
database start from the Aspen EDR number 5000 (5000-5999). The new
database filenames for the engine are AS2290P.PDA and NAS2290I.PDA. The
user selects the usage of code case 2290 by selecting any available material
in the 5000 series.
 General
Perry's Chemical Engineers' Handbook, Sixth Edition, McGraw-Hill, 1984
General Discussion on Heat Transfer, Institution of Mechanical Engineers
London, 1951
Practical Aspects of Heat Transfer, AIChE Technical Manual, 1976
Gas Engineers Handbook, C. George Segeler, Industrial Press, 1974
Heat Transfer and Fluid Flow Data Books, General Electric, 1984
Engineering Data Book, Gas Processors Suppliers Association, 1979
Standard Handbook of Engineering Calculations, Second Edition, Tyler G.
Hicks, McGraw-Hill, 1985
Heat Exchanger Design Handbooks, Volumes 1-5, Hemisphere Publishing
Corporation, 1984
International Heat Transfer Conference Proceedings, Hemisphere Publishing
Corporation,
Heat Transfer 1978, Toronto
Heat Transfer 1982, Munich
Heat Transfer 1986, San Francisco
Heat Transfer 1990, Jerusalem
AIChE Symposium Heat Transfer Series
Seattle 82 Volume 64, 1968
Philadelphia 92 Volume 65, 1969
Minneapolis 102 Volume 66, 1970
Tulsa 118 Volume 68, 1972
Fundamentals 131 Volume 69, 1973
Research & Design 138 Volume 70, 1974
St. Louis 164 Volume 73, 1977
Research & Application 174 Volume 74, 1978
Seattle 225 Volume 79, 1983
Niagara Falls 236 Volume 80, 1984
Denver 245 Volume 81, 1985
Process Heat Transfer, Donald Q. Kern, McGraw-Hill, 1950
Compact Heat Exchangers, Third Edition, Kays & London, McGraw-Hill, 1984
Process Design for Reliable Operations, Norman P. Lieberman, Gulf Publishing
Company, 1983
Heat Exchangers: Design and Theory Sourcebook, Afgan & Schlunder,
McGraw Hill, 1974
Heat Exchangers Thermal-Hydraulic Fundamentals and Design, Kakac, Bergles
& Mayinger, McGraw-Hill, 1981
Convective Boiling and Condensation, John G. Collier, McGraw-Hill, 1972
Industrial Heat Exchangers, A Basic Guide, G. Walker, McGraw-Hill, 1982
Heat Transfer, J.P. Holman, McGraw-Hill, 1981
Heat Transfer in Counterflow, Parallel Flow and Cross Flow, Helmuth Hausen,
McGraw-Hill, 1983
Extended Surface Heat Transfer, D.O. Kern & A.D. Kraus, McGraw-Hill, 1972
Heat Exchangers, Theory and Practice, Taborek, Hewitt & Afgan, McGraw-Hill,
1983
Two-Phase Flow and Heat Transfer in the Power and Process Industries,
Bergles, Collier, Delhaye, Hewitt & Mayinger, McGraw-Hill, 1981
Standards of Tubular Exchangers Manufacturers Association, Seventh Edition,
TEMA, 1988
Wolverine Trufin Engineering Data Book, Wolverine Tube Division, 1967
Heat Transfer Pocket Handbook, Nicholas P. Cheremisinoff, Gulf Publishing
Company, 1984
Fluid Flow Pocket Handbook, Nicholas P. Cheremisinoff, Gulf Publishing
Company, 1984
Handbook of Chemical Engineering Calculations, Chopey & Hicks, McGraw-Hill,
1984
Heat Exchangers for Two-Phase Applications, ASME, HTD-Vol. 27, 1983
Reprints of AIChE Papers, 17th National Heat Transfer Conference, Salt Lake
City, 1977
Standards for Power Plant Heat Exchangers, Heat Exchange Institute Inc.,
1980
A Reappraisal of Shell side Flow in Heat Exchangers, ASME HTD-36, 1984
Shell side Waterflow Pressure Drop and Distribution in Industrial Size Test
Heat Exchanger, Halle & Wambsganss, Argonne National Laboratory, 1983
Basic Aspects of Two Phase Flow and Heat Transfer, ASME, HTD-Vol. 34, 1984
ASME Heat Transfer Publications, 1979, 18th National Heat Transfer
Conference, Condensation Heat Transfer, & Advances in Enhanced Heat
Transfer
Shell and Tube Heat Exchangers, Second Symposium, American Society for
Metals, Houston, Texas, September, 1981
Two-Phase Heat Exchanger Symposium 23rd National Heat Transfer
Conference, Denver, Colorado, HTD-Vol.44 August, 1985
Advances in Enhanced Heat Transfer 23rd National Heat Transfer Conference,
Denver, Colorado, HTD-Vol.43 August, 1985
Heat Tranfer Equipment Design, R.K. Shah, Subbarao, and R.A. Mashelkar,
Hemisphere Publishing Corporation, 1988
Heat Transfer Design Methods, Edited by John J. McKetta, Marcel Dekker Inc.,
1992
Boilers Evaporators & Condesers, Sadik Kakac, John Wiley & Sons Inc., 1991
Enhanced Boiling Heat Transfer, John R. Thome, Hemisphere Publishing
Corporation, 1990
Handbook of Heat Transfer Applications Second Edition Editors W.M.
Rohsenow, J.P. Hartnett and Ejup N. Ganic, McGraw-Hill Book Co., 1985
Piping Handbook, Sixth Edition, Mobinder L. Nayyar, McGraw-Hill Inc., 1992
Practical Aspects of Heat Transfer, Proceedings of 1976 Fall Lecture Series of
New Jersey-- North Jersey Sections of AICHE, 1976.
Air Cooled Heat Exchangers For General Refinery Services, API Standard 661
Second Edition, January 1978.
ESCOA Fintube Manual, Chris W. Weierman, ESCOA Fintube Corporation
Moore Fan Company Manual, Moore Fan Company, 1982.
Heat Transfer: Research and Application, ed. John Chen, AIChE Symposium
Series, No. 174, Vol. 74, 1978
Heat Transfer—Seattle 1983, Nayeem M. Farukhi, AIChE Symposium Series,
No. 225, Vol. 79, 1983.
Principles of Heat Transfer, Frank Kreith, International Textbook Company,
1958.
Fundamentals of Heat Transfer, S. S. Kutateladze, Academic Press, 1963.
NGPSA Engineering Data Book, Natural Gas Processors Suppliers Association,
1979.
“Design of Air-Cooled Exchangers,” Robert Brown, Chemical Engineering,
March 27, 1978.
“Process Design Criteria,” V. Ganapathy, Chemical Engineering, March 27,
1978.
 Stream Analysis Type Correlations
Shell Side Characteristics of Shell and Tube Heat Exchangers, Townsend
Tinker, ASME Paper No. 56-A-123.
Exchanger Design Based on the Delaware Research Program, Kenneth J. Bell,
PETRO/CHEM, October, 1960
Heat Exchanger Vibration Analysis, A. Devore, A. Brothman, and A. Horowitz,
Practical Aspects of Heat Transfer, (Proceedings of 1976 Fall Lecture Series of
New Jersey), AIChE
The Effect of Leakage Through the Longitudinal Baffle on the Performance of
Two-Pass Shell Exchangers, T. Rozenman and J. Taborek AIChE Symposium
Series Heat Transfer Tulsa 118, Volume 68, 1972
Patterns of Fluid Flow in a Shell-and-Tube Heat Exchanger, J.A. Perez and
E.M. Sparrow, Heat Transfer Engineering, Volume 5 Numbers 3-4, 1984,
Hemisphere Publishing Corporation
Solution of Shell Side Flow Pressure Drop and Heat Transfer, Stream Analysis
Method, J.W. Palen and Jerry Taborek, AIChE Symposium Series Heat
Transfer-Philadelphia 92, Volume 65, 1969
Shell side Waterflow Pressure Drop and Distribution in Industrial Size Test
Heat Exchanger, H. Halle and M.W. Wambsganss, ANL-83-9 Argonne National
Laboratory, 1983
A Reappraisal of Shell side Flow in Heat Exchangers, HTD-Vol. 36, ASME,
1984
Delaware Method for Shell Side Design, Kenneth J. Bell, Heat Exchangers
Thermal-Hydraulic Fundamentals and Design, McGraw-Hill Book Co., 1981
 Low Fin Tube Correlations
Handbook of Chemical Engineering Calculations, Nicholas P. Chopey and Tyler
G. Hicks, McGraw-Hill Book Co., 1984
Wolverine Trufin Engineering Data Book, Wolverine Division, UOP Inc.
Fine-Fin Tubing Specifications, High Performance Tube Inc., 2MI/78
 Transfer Rates at the Caloric Temperature
Improved Exchanger Design, Riad G. Malek, Hydrocarbon Processing, May
1973
Process Heat Transfer, Donald Q. Kern, McGraw Hill Book Co., 1950
The Caloric Temperature Factor for a 1-2 Heat Exchanger with An Overall
Heat Transfer Coefficient Varying Linearly with Tube Side Temperature, R.B.
Bannerot and K.K. Mahajan, AIChE Symposium Series 174, Volume 74, Heat
Transfer - Research and Applications, 1978
 Grid Baffle Correlations
The Energy-Saving NESTS Concept, Robert C. Boyer and Glennwood K. Pase,
Heat Transfer Engineering, Vol. 2, Number 1, Hemisphere Publishing
Corporation, July-Sept. 1980
Thermal Design Method for Single-Phase RODBaffle Heat Exchangers, C.C.
Gentry and W.M. Small, Phillips Petroleum Company, 1981
RODbaffle Exchanger Thermal-Hydraulic Predictive Models Over Expanded
Baffle-Spacing and Reynolds Number Ranges, C. C. Gentry and W. M. Small,
AIChE Symposium Series 245, Vol 81 Heat Transfer-Denver, 1985
RODbaffle Heat Exchanger Thermal-Hydraulic Predictive Methods for Bare and
Low-Finned Tubes, C. C. Gentry, R. K. Young, W. M. Small, AIChE Symposium
Series Heat Transfer - Niagara Falls 236, Volume 80, 1984
 Phase Change - Natural and Forced Circulation
Boiling
Thermal Design of Horizontal Reboilers, James R. Fair and Abraham Klip,
Chemical Engineering Progress, March 1983
Two-Phase Flow and Heat Transfer in the Power and Process Industries, A. E.
Bergles, J. G. Collier, J. M. Delhaye, G. F. Hewitt, and F. Mayinger, McGraw-
Hill, 1981
Circulation Boiling, Model for Analysis of Kettle and Internal Reboiler
Performance, J. W. Palen and C. C. Yang, Heat Exchangers for Two-Phase
Applications, ASME HTD-Vol 27, July 1983.
A Prediction Method for Kettle Reboilers Performance, T. Brisbane, I. Grant
and P. Whalley, ASME 80-HT-42
Nucleate Boiling: A Maximum Heat Flow Correlation for Corresponding States
Liquids, C. B. Cobb and E. L. Par, Jr., AIChE Symposium Series Heat Transfer
Philadelphia 92, Volume 65, 1969
Boiling Coefficients Outside Horizontal Plain and Finned Tubes, John E. Myers
and Donald L. Katz, Refrigerating Engineering, January, 1952
Forced Crossflow Boiling in an Ideal In-Line Tube Bundle, G. T. Pooley, T.
Ralston, and I. D. R. Grant, ASME 80-HT-40
Characteristics of Boiling Outside Large-Scale Horizontal Multitube Bundles, J.
W. Palen, A. Yarden, and J. Taborek, AIChE Symposium Series Heat Transfer -
Tulsa 118, Volume 68, 1972
A Simple Method for Calculating the Recirculating Flow in Vertical
Thermosyphon and Kettle Reboilers", P.B. Whalley and D. Butterworth, Heat
Exchangers for Two-Phase Applications, ASME HTD-Vol.27, July 1983
Analysis of Performance of Full Bundle Submerged Boilers, By P. Payvar, Two-
Phase Heat Exchanger Symposium, ASME HTD-Vol.44, August 1985
Enhanced Boiling Heat Transfer, Hemisphere Publishing Corporation, 1990
 Phase Change Condensation
Handbook of Chemical Engineering Calculations, Nicholas P. Chopey and Tyler
G. Hicks, McGraw-Hill Book Company, 1984
Heat Transfer and Two-Phase Flow During Shell-Side Condensation, P. J.
Marto, Heat Transfer Engineering, Vol. 5, Number 1-2, 1984
Process Heat Transfer, Donald Q. Kern, McGraw-Hill Book Company, 1950
Design Parameters for Condensers and Reboilers, P. C. Lord, R. E. Minton and
R. P. Slusser, Chemical Engineering, March 23, 1970
Condensation of Immiscible Mixtures, S. H. Bernhardt, J.J. Sheridan, and J.
W. Westwater, AIChE Symposium Heat Transfer-Tulsa No. 118, Vol. 68, 1972
Design of Cooler Condensers for Mixtures of Vapor with Noncondensing Gases,
A. P. Colburn and O. A. Hougen, Industrial and Engineering Chemistry,
November 1939
Simplify Design of Partial Condensers, J. Starzewski, Hydrocarbon Processing,
March 1981
Calculate Condenser Pressure Drop, John E. Diehl, Petroleum Refiner, October
1957
Two-Phase Pressure Drop for Horizontal Crossflow Through Tube Banks, J. E.
Diehl and C. H. Unruh, Petroleum Refiner, October 1958
Mean Temperature Difference for Shell-And-Tube Heat Exchangers with
Condensing on the Shell Side, Robert S. Burligame, Heat Transfer
Engineering, Volume 5, Numbers 3-4, 1984
An Assessment of Design Methods for Condensation of Vapors from a
Noncondensing Gas, J. M. McNaught, Heat Exchanger Theory and Practice,
McGraw-Hill Book Co., 1983
A Multicomponent Film Model Incorporating a General Matrix Method of
Solution to the Maxwell-Stefan Equations, AIChE Journal, Vol 22, March 1976
Modified Resistance Proration Method for Condensation of Vapor Mixtures, R.
G. Sardesai, J. W. Palen, and J. Taborek, AIChE Symposium Series Heat
Transfer - Seattle 225, Volume 79, 1983
An Approximate Generalized Design Method for Multicomponent Partial
Condensers, K. J. Bell and M. A. Ghaly, AIChE Symposium Series Heat
Transfer No. 131, Vol 69, 1973
Rating Shell-and-Tube Condensers by Stepwise Calculations, R. S. Kistler, A.
E. Kassem, and J. M. Chenoweth, ASME 76-WA/HT-5, 1976
Two-Phase Flow on the Shell-Side of a Segmentally Baffled Shell-and-Tube
Heat Exchanger, I. D. R. Grant and D. Chismolm, ASME 77-WA/HT-22, 1977
Shell side Flow in Horizontal Condensers, I. D. R. Grant, D. Chisholm, and C.
D. Cotchin, ASME 80-HT-56, 1980
Critical Review of Correlations for Predicting Two-Phase Flow Pressure Drop
Across Tube Banks, K. Ishihara, J. W. Palen, and J. Taborek, ASME 77-WA/HT-
23
Design of Binary Vapor Condensers Using the Colburn-Drew Equations, B C.
Price and K. J. Bell, AIChE Symposium Series No. 138, Volume 74, 1974
Theoretical Model for Condensation on Horizontal Integral-Fin Tubes, T.M.
Rudy and R. L. Webb, AIChE Symposium Series Heat Transfer Seattle 225,
Volume 79, 1983
Condensers: Basic Heat Transfer and Fluid Flow, D. Butterworth, Heat
Exchangers Thermal-Hydraulic Fundamentals and Design, McGraw-Hill Book
Company, 1981
Condensers: Thermohydraulic Design, D. Butterworth, Heat Exchangers
Thermal-Hydraulic Fundamentals and Design, McGraw-Hill Book Company,
1981
 High Fin Heat Transfer & Pressure Drop
“Fired Heaters,” Herbert L. Berman, Chemical Engineering, June 19, 1978.
“Bond Resistance of Bimetalic Finned Tubes,” E.H. Young and D. E. Briggs,
Chemical Engineering Progress, Vol. 61, No. 7, July 1965.
“Efficiency of Extended Surface,” Karl A. Gardner, Transactions of the ASME,
November, 1945.
Heat Transfer 1978: Sixth International Heat Transfer Conference, Vol. 1-6
Washington, D. C., Hemisphere Publishing Corporation, 1978
“Pressure Drop of Air Flowing Across Triangular Pitch Banks of Finned Tubes,”
K. Robinson and D. E. Briggs, Eighth National Heat Transfer Conference, Los
Angeles, California, August, 1965.
“Convective Heat Transfer and Pressure Drop of Air Flowing Across Triangular
Pitch Banks of Finned Tubes,” D. E. Briggs and E. Young, Chemical
Engineering Progress Symposium Series, No. 64, Vol. 62, 1966.
“Tube Spacing in Finned-Tube Banks,” S. L. Jameson, Transactions of the
ASME, Vol. 67, November 1945.
“Pressure Drop of Air Flowing Across Triangular Pitch Banks of Finned Tubes,”
K. Robinson and D. E. Briggs, Chemical Engineering Progress Symposium
Series, No. 64, Vol. 62, 1966.
”Comparison of Performance of Inline and Staggered Banks of Tubes with
Segmented Fins,” AIChE-ASME 15th National Heat Transfer Conference, San
Francisco, 1975.
“Efficiency of Extended Surfaces,“ Karl Gardner, Transactions of ASME,
November 1945.
“Thermal Contact Resistance in Finned Tubing,” Karl Gardner and T. C.
Carnavos, Journal of Heat Transfer, November 1960.
ESCOA Fintube Manual, Chris W. Weierman ESCOA Fintube Corporation.
 No Phase Change
Process Heat Transfer, Donald Q. Kern, McGraw-Hill Book Co. 1950
Improved Exchanger Design, Transfer Rates at the Caloric Temperature, Riad
G. Malek, Hydrocarbon Processing, May 1973
Heat Transfer Colburn-Factor Equation Spans All Fluid Flow Regimes, Bill L.
Pierce, Chemical Engineering, December 17, 1979
An Improved Heat Transfer Correlation for Laminar Flow of High Prandtl
Number Liquids in Horizontal Tubes, By J. W. Palen, and J. Taborek, AIChE
Symposium Series Heat Transfer-Denver 245, Volume 81, 1985
The Caloric Temperature Factor for a 1-2 Heat Exchanger with an Overall
Heat Transfer Coefficient Varying Linearly with Tube Side Temperature, P. B.
Bannerot and K. K. Mahajan, AIChE Symposium Series 174, Volume 74, 1978
Turbulent Heat Transfer and Pressure Drop in Internally Finned Tubes, A. P.
Watkinson, D. L. Miletti and P. Tarassoff, AIChE Symposium Series 131,
Volume 69, 1973
The Computation of Flow in a Spirally Fluted Tube, A. Barba, G. Bergles, I.
Demirdzic, A. D. Godman, and B. E. Lauder, AIChE Symposium Series Heat
Transfer-Seattle 225, Volume 79, 1983
Investigation of Heat Transer Inside Horizontal Tubes in the Laminar Flow
Region, P. Buthod, University of Tulsa Report, 1959
Design Method for Tube-Side Laminar and Transition Flow Regime Heat
Transfer With Effects of Natural Convection, 9th International Heat Transfer
Conference, Open Forum Session, Jerusalem, Israel, 1990
 Phase Change - Natural and Forced Circulation
Boiling
Simulated Performance of Refrigerant-22 Boiling Inside Tubes in a Four Tube
Pass Shell and Tube Heat Exchanger, By John F. Pearson and Edwin H. Young,
AIChE Symposium Series Heat Transfer-Minneapolis 102, Volume 66, 1970
Heat Transfer to Boiling Refrigerants Flowing Inside a Plain Copper Tube, B.
W. Rhee and E. H. Young, AIChE Symposium Series 138, Volume 70, 1974
An Improved Correlation for Predicting Two-Phase Flow Boiling Heat Transfer
Coefficient in Horizontal and Vertical Tubes, S. G. Kandliker, Heat Exchanger
for Two-Phase Applications, ASME HTD-Vol. 27, July 1983
A Simple Method for Calculating the Recirculating Flow in Vertical
Thermosyphon and Kettle Reboilers, P. B. Whalley and D. Butterworth, Heat
Exchangers for Two-Phase Applications, ASME HTD-Vol. 27, July 1983
Performance Prediction of Falling Film Evaporators, K.R. Chun and R. A.
Seban, ASME 72 HT-48
Thermal Design of Horizontal Reboilers, James R. Fair and Abraham Klip,
Chemical Engineering Progress, March 1983
What You Need To Design Thermosiphon Reboilers, J. R. Fair, Petroleum
Refiner, February 1960
Vaporizer and Reboiler Design Part 1, James R. Fair, Chemical Engineering,
July 8, 1963
Vaporizer and Reboiler Design Part 2, James R. Fair, Chemical Engineering,
August 5, 1963
Mist Flow in Thermosiphon Reboilers, J. W. Palen, C.C. Shih and J. Taborek,
Chemical Engineering Progress, July 1982
A Computer Design Method for Vertical Thermosyphon, N. V. L. S. Sarma, P.
J. Reddy, and P.S. Murti, Industrial Engineering Chemistry Process Design
Development, Vol. 12, No. 3, 1973
Designing Thermosiphon Reboilers, G. A. Hughmark, Chemical Engineering
Progress, Vol. 65, No. 7, July 1969
Design of Falling Film Absorbers, G. Guerrell and C. J. King, Hydrocarbon
Processing, January 1974
Heat Transfer to Evaporating Liquid Films, K. R. Chun and R. A. Seban ASME
71-HT-H
Performance of Falling Film Evaporators, F. R. Whitt, British Chemical
Engineering, December 1966, Vol. 11, No. 12
Selecting Evaporators, D. K. Mehra, Chemical Engineering, February 1986
Heat Transfer in Condensation Boiling, Karl Stephan, Springer-Verlag, 1988
Flow Boiling Heat Transfer in Vertical Tubes Correlated by Asympotic Model,
Dieter Steiner and Jerry Taborek, Heat Transfer Engineering Vol. No. 2, 1992
 Phase Change Condensation
Flooding Velocity Correlation for Gas-Liquid Counterflow in Vertical Tubes, J.
E. Diehl and C. R. Koppany, AIChE Symposium Series Heat Transfer-
Philadelphia 92, Volume 65, 1969
Interpretation of Horizontal In-Tube Condensation Heat Transfer Correlations
with a Two-Phase Flow Regime Map, K. J. Bell, J. Taborek, and F. Fenoglio,
AIChE Symposium Series Heat Transfer-Minneapolis 102, Volume 66, 1970
Filmwise Condensation of Light Hydrocarbons and Their Mixtures in a Vertical
Reflux Condenser, L. D. Clements and C. P. Colver, AIChE Symposium Series
131, Volume 69, 1973
Prediction of Horizontal Tube side Condensation of Pure Components Using
Flow Regime Criteria, G. Breber, J. Palen & J. Taborek, ASME Condensation
Heat Transfer, August 1979
Prediction of Flow Regimes in Horizontal Tube side Condensation, J. Palen, G.
Breber, and J. Taborek, AIChE 17th National Heat Transfer Conference Salt
Lake City, Utah, August 1977
Condensers: Basic Heat Transfer and Fluid Flow, D. Butterworth, Heat
Exchangers Thermal-Hydraulic Fundamentals and Design, McGraw-Hill Book
Company, 1981
Prediction of Horizontal Tube side Condensation Using Flow Regime Criteria,
Condensation Heat Transfer, National Heat Transfer Conference, San Diego,
1979, ASME 1979
 Vibration Analysis
Natural Frequencies and Damping of Tubes on Multiple Supports, R. L. Lowery
and P.M. Moretti, AIChE Symposium Series 174, Volume 74, 1978
Tube Vibrations in Shell-And-Tube Heat Exchangers, J. M. Chenoweth and R.
S. Kistler, AIChE Symposium Series 174, Volume 74, 1978
Critical Review of the Literature and Research on Flow-Induced Vibrations in
Heat Exchangers, P.M. Moretti, AIChE Symposium Series 138, Volume 70,
1974
Vibration in Heat Exchangers, Franz Mayinger and H. G. Gross, Heat
Exchangers Thermal-Hydraulic Fundamentals and Design, McGraw Hill Book
Company, 1981
Predict Exchanger Tube Damage, J. T. Thorngren, Hydrocarbon Processing,
April 1970
Flow-Induced Tube Vibration Tests of Typical Industrial Heat Exchanger
Configurations, H. Halle, J. M. Chenoweth and M. W. Wambsganss, ASME 81-
DET-37
 Fans
Moore Fan Company Manual, Moore Fan Company, 1982.
“Specifying and Rating Fans,” John Glass, Chemical Engineering, March 27,
1978.
 TEMA
Design Fouling Resistances

TEMA: Tubular Exchangers Manufacturers Association: www.tema.org

 TEMA Design Fouling Resistances
The following data is taken from TEMA RGP-T-2.4
The purchaser should attempt to select an optimal fouling resistance that will
result in a minimum sum of fixed, shutdown and cleaning costs. The following
tabulated values of fouling resistances allow for oversizing the heat
exchanger so that it will meet performance requirements with reasonable
intervals between shutdowns and cleaning. These values do not recognize the
time related behavior of fouling with regard to specific design and operational
characteristics of particular heat exchangers.

Fouling Resistances for Industrial Fluids

Fouling Resistances for Chemical Processing Systems
Fouling Resistances for Natural Gas-Gasoline Processing Systems
Fouling Resistances for Oil Refinery Streams
Fouling Resistances for Water
 TEMA Fouling Resistances for Industrial Fluids
Oils:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00035
Fuel Oil #2
(0.002)

0.00088
Fuel Oil #6
(0.005)

0.00018
Transformer Oil
(0.001)

0.00018
Engine Lube Oil
(0.001)

0.0007
Quench Oil
(0.004)

Gases and Vapors:

m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00176
Manufactured Gas
(0.010)

0.00176
Engine Exhaust Gas
(0.010)

Steam 0.00088
(Non-Oil Bearing) (0.005)

Exhaust steam 0.00026 – 0.00035

(oil bearing) (0.0015 – 0.002)

Refrigerant Vapors 0.00035

(Oil Bearing) (0.002)

0.00018
C ompressed Air
(0.001)

0.00018
ammonia Vapor
(0.001)

0.00018
C O2 Vapor
(0.001)

0.00035
C hlorine
(0.002)

0.00176
C oal Flue Gas
(0.010)

0.00088
Natural Gas Flue Gas
(0.005)
Liquids:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00009
Molten Heat Transfer Salts
(0.0005)

0.00018
Refrigerant Liquids
(0.001)

0.00018
Hydraulic Fluid
(0.001)

Industrial Organic Heat 0.00035

Transfer Media (0.002)

0.00018
Ammonia Liquid
(0.001)

Ammonia Liquid (Oil 0.00053

Bearing) (0.003)

0.00053
C alcium C hloride Solutions
(0.003)

0.00053
Sodium C hloride Solutions
(0.003)

0.00018
C O2 Liquid
(0.001)

0.00035
C hlorine Liquid
(0.002)

0.00035
Methanol Solutions
(0.002)

0.00035
Ethanol Solutions
(0.002)

0.00035
Ethylene Glycol Solutions
(0.002)
 TEMA Fouling Resistances for Chemical
Processing Systems
Gases and Vapors:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00035 – 0.00053
Acid Gases
(0.002 – 0.003)

0.00018
Solvent Vapors
(0.001)

0.00018
Stable Overhead Products
(0.001)

Liquids:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00035
MEA And DEA Solutions
(0.002)

0.00035
DEG And TEG Solutions
(0.002)

Stable Side Draw And 0.00018 – 0.00035

Bottom Product (0.001 – 0.002)

0.00035
C austic Solutions
(0.002)

0.00053
Vegetable Oils
(0.003)
 TEMA Fouling Resistances for Natural Gas-
Gasoline Processing Systems
Gases and Vapors:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00018 – 0.00035
Natural Gas
(0.001 – 0.002)

0.00018 – 0.00035
Overhead Products
(0.001 – 0.002)

Liquids:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00035
Lean Oil
(0.002)

0.00018 – 0.00035
Rich Oil
(0.001 – 0.002)

Natural Gasoline and 0.00018 – 0.00035

Liquefied Petroleum Gases (0.001 – 0.002)
 TEMA Fouling Resistances for Oil Refinery
Streams
Crude and Vacuum Unit Gases And Vapors:
m^2 deg K/W
(hr ft^2 deg F/BTU)

Atmospheric Tower 0.00018

Overhead Vapors (0.001)

0.00018
Light Naphthas
(0.001)

0.00035
Vacuum Overhead Vapors
(0.002)

m^2 deg K/W

Crude and Vacuum Liquids:
(hr ft^2 deg F/BTU)

0 to 121 deg C
Temperature
(0 to 250 deg F)

<0.6 m/sec 0.6-1.2 m/sec >1.2 m/sec

Velocity
(<2 ft/sec) (2-4 ft/sec) (>4 ft/sec)

0.00053 0.00035 0.00035

DRY
(0.003) (0.002) (0.002)

0.00053 0.00035 0.00035

SALT*
(0.003) (0.002) (0.002)

C rude Oil

121 to 177 deg C

Temperature
(250 to 350 deg F)

<0.6 m/sec 0.6-1.2 m/sec >1.2 m/sec

Velocity
(<2 ft/sec) (2-4 ft/sec) (>4 ft/sec)

0.00053 0.00035 0.00035

DRY
(0.003) (0.002) (0.002)

0.00088 0.0007 0.0007

SALT*
(0.005) (0.004) (0.004)

177 to 232 deg C

Temperature
(350 to 450 deg F)

< 0.6 m/sec 0.6 - 1.2 m/sec >1.2 m/sec

Velocity
(< 2 ft/sec) (2 - 4 ft/sec) (> 4 ft/sec)
 0.0007 0.00053 0.00053
DRY
(0.004) (0.003) (0.003)

0.00106 0.00088 0.00088

SALT*
(0.006) (0.005) (0.005)

232 deg C and over

Temperature
(450 deg F and over)

< 0.6 m/sec 0.6 - 1.2 m/sec > 1.2 m/sec

Velocity
(< 2 ft/sec) (2 - 4 ft/sec) (> 4 ft/sec)

0.00088 0.0007 0.0007

DRY
(0.005) (0.004) (0.004)

0.00123 0.00106 0.00106

SALT*
(0.007) (0.006) (0.006)

*Assumes desalting @ approximately (250 deg F)

m^2 deg K/W

(hr ft^2 deg F/BTU)

0.00035
Gasoline
(0.002)

0.00035 – 0.00053
Naphtha And Light Distillates
(0.002 – 0.003)

0.00035 – 0.00053
Kerosene
(0.002 – 0.003)

0.00035 – 0.00053
Light Gas Oil
(0.002 – 0.003)

0.00053 – 0.00088
Heavy Gas Oil
(0.003 – 0.005)

0.00088 – 0.00123
Heavy Fuel Oils
(0.005 – 0.007))

Asphalt And Residuum:

m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00176
Vacuum Tower Bottoms
(0.010)

0.00123
Atmosphere Tower Bottoms
(0.007)

Cracking And Coking Unit Streams:

m^2 deg K/W
 (hr ft^2 deg F/BTU)

0.00035
Overhead Vapors
(0.002)

0.00035 – 0.00053
Light C ycle Oil
(0.002 – 0.003)

0.00053 – 0.0007
Heavy C ycle Oil
(0.003 – 0.004)

0.00053 – 0.0007
Light C oker Gas Oil
(0.003 – 0.004)

0.0007 – 0.00088
Heavy C oker Gas Oil
(0.004 – 0.005)

Bottoms Slurry Oil (4.5 Ft/Sec 0.00053

Minimum) (0.003)

0.00035
Light Liquid Products
(0.002)

Catalytic Reforming, Hydrocracking and Hydrodesulfurization Streams:

m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00026
Reformer C harge
(0.0015)

0.00026
Reformer Effluent
(0.0015)

Hydrocracker C harge And 0.00035

Effluent* (0.002)

0.00018
Recycle Gas
(0.001)

Hydrodesulfurization C harge And 0.00035

Effluent* (0.002)

0.00018
Overhead Vapors
(0.001)

0.00018
Liquid Product Over 50 ° A.P.I.
(0.001)

0.00035
Liquid Product 30 - 50 ° A.P.I.
(0.002)

*Depending on charge, characteristics and storage history, charge

resistance may be many times this value

Light Ends Processing Streams:

m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00018
Overhead Vapors And Gases (0.001)

0.00018
Liquid Products
(0.001)

0.00035 – 0.00053
Absorption Oils
(0.002 – 0.003)

0.00035
Alkylation Trace Acid Streams
(0.002)

0.00035 – 0.00053
Reboiler Streams
(0.002 – 0.003)

Lube Oil Processing Streams:

m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00035
Feed Stock
(0.002)

0.00035
Solvent Feed Mix
(0.002)

0.00018
Solvent
(0.001)

0.00053
Extract*
(0.003)

0.00018
Raffinate
(0.001)

0.00088
Asphalt
(0.005)

0.00053
Wax Slurries*
(0.003)

0.00018
Refined Lube Oil
(0.001)

*Precautions must be taken to prevent wax deposition on cold tube walls.

Visbreaker:
m^2 deg K/W
(hr ft^2 deg F/BTU)

0.00053
Overhead Vapor
(0.003)

0.00176
Visbreaker Bottoms
(0.010)

Naphtha Hydrotreater:
m^2 deg K/W
 (hr ft^2 deg F/BTU)

0.00053
Feed
(0.003)

0.00035
Effluent
(0.002)

0.00035
Naphthas
(0.002)

0.00026
Overhead Vapors
(0.0015)

Catalytic Hydro Desulfurizer:

m^2 deg K/W
(hr ft^2 deg F/BTU)

0.0007 – 0.00088
C harge
(0.004 – 0.005)

0.00035
Effluent
(0.002)

0.00035
H.T. Sep. Overhead
(0.002)

0.00053
Stripper C harge
(0.003)

0.00035
Liquid Products
(0.002)

HF Alky Unit:
m^2 deg K/W
(hr ft^2 deg F/BTU)

Alkylate, Deprop. Bottoms, Main

0.00053
Fraction,
(0.003)
Overhead Main Fraction Feed

0.00035
All Other Process Streams
(0.002)
 TEMA Fouling Resistances for Water
Temperature of Up to 116 deg C 116 to 204 deg C
Heating Medium (Up To 240 deg F) (240 to 400 deg F)

Temperature of 52 deg C 52 deg C

Water (125 deg F) (125 deg F)

< = 0.9 m/sec > 0.9 m/sec < = 0.9 m/sec

Water Velocity Water Velocity
(< = 3 ft/sec) (> 3 ft/sec) (< = 3 ft/sec)

0.00088 0.00088 0.00088

Sea Water Sea Water
(0.005) (0.005) (0.005)

0.00035 0.00018 0.00035

Brackish Water Brackish Water
(0.002) (0.001) (0.002)

Cooling Tower And Artificial Spray Pond:

0.00018 0.00018 0.00035 0.00035

Treated Make Up
(0.001) (0.001) (0.002) (0.002)

0.00053 0.00053 0.00088 0.0007

Untreated
(0.003) (0.003) (0.005) (0.004)

C ity Or Well 0.00018 0.00018 0.00035 0.00035

Water (0.001) (0.001) (0.002) (0.002)

River Water:

0.00035 0.00018 0.00053 0.00035

Minimum
(0.002) (0.001) (0.003) (0.002)

0.00053 0.00035 0.0007 0.00053

Average
(0.003) (0.002) (0.004) (0.003)

0.00053 0.00035 0.0007 0.00053

Muddy or Silty
(0.003) (0.002) (0.004) (0.003)

Hard (Over 15 0.00053 0.00053 0.00088 0.00088

Grains/Gal.) (0.003) (0.003) (0.005) (0.005)

0.00018 0.00018 0.00018 0.00018

Engine Jacket
(0.001) (0.001) (0.001) (0.001)

Distilled or Closed Cycle:

0.00088 0.00088 0.00088 0.00088

C ondensate
(0.005) (0.005) (0.005) (0.005)

Treated Boiler 0.00018 0.00088 0.00018 0.00018

Feedwater (0.001) (0.005) (0.001) (0.001)

0.00035 0.00035 0.00035 0.00035

Boiler Blowdown
(0.002) (0.002) (0.002) (0.002)

If the heating medium temperature is over 204 deg C (400 deg F) and the cooling medium is known
to scale, these ratings should be modified accordingly.
 Tube Layout: Editing
When Shell&Tube is run, a tube layout is created and used as input to the
next run. This tube layout can be edited. However, the Tube Layout which
appears in the output cannot be edited.
Editing the tube layout for input can be time consuming and should be treated
as a last resort. Before editing, you should aim to get an automatically
generated layout which is as close as possible to the layout you want. Using
the Pass details option, you can specify the exact location of every tube pass
and the number of rows and columns of tubes in each pass.
To edit the tube layout, you must be in a Checking or Simulation mode and
select Use existing layout as the Tube Layout option under the main
geometry input. Then go to the Tube Layout tab to view and edit the layout.
You can move objects around the layout and add or remove tubes and tie
rods. You cannot add or remove major features such as impingement plates,
but in some cases you can resize them.
In the drop-down list of object types of in the layout, select an item in the list
to view a table of all such objects and their associated parameters. Some of
these parameters are editable.

See Shell&Tube: Tube Layout for a basic list of object types.

See also:
Tube Layout: Moving objects
Tube Layout: Adding and Removing Tubes
Tube Layout: Other Facilities
 Tube Layout: Moving objects
The parameters of an object normally include the x and y co-ordinates of the
center of the object. One method of moving an object is simply to change
these parameters to required values.
A more convenient method of moving an object is to select it, and then use
the nudge buttons that appear when you select an object capable of being
moved. You must first enter a distance associated with one nudge; 1mm is a
typical value, but you can use larger or smaller values. The four arrows let
you nudge the object in any direction by that amount.
Note that it is up to you to put the object in a sensible location. Except in a
very few cases, there are no imposed constraints against objects being placed
in non-physical situations. Note also that not every change of location has an
effect on program results. For example, the results are affected by the
number of sealing strips, but not by the size or location of individual strips.
When a layout is generated, tie rods will normally be placed in a sensible
location, even if this means removing a tube. There is however an input
option to not replace tubes. In such cases tie rod locations will be
inappropriate, and often unphysical; you will need to select and then move
the tie rod.

See also:
Tube Layout: Adding and Removing Tubes
Tube Layout: Other Facilities
 Tube Layout: Adding and Removing Tubes
Tubes are defined by Tube Line objects, which define the location of the first
and last tubes in a line. A set of tube lines is contained within a Pass Region.
A pass region is defined by four lines (a rectangle) and a circular limit,
defined by its radius and concentric with the shell. If you move a pass region,
all the tubes in the region move with it, preserving the tube pattern.
However, since tube layouts are generated making full use of available space
within the shell, there is often very little scope for moving pass regions, so
this is not advised.
Tube lines are normally horizontal, but the Pass Layout has been specified as
being vertical in the main input; tube lines will be vertical, so that Right/Left
is interchanged with Top/Bottom. See Shell&Tube Pass Layout Orientation.
If you right-click on tube, then the Tube Line containing the tube is
highlighted in red, and the selected tube is solid red. A drop down appears
offering various options. These include
· Deleting the tube line.
· Deleting the selected tube. If the tube is in the middle of the line, the
line fragments either side of it will become two separate tube lines.
· Converting the selected tube to a tie rod. If the tube is not on the end of
the line, this will also generate an extra line.
· Adding a tube to the left- or right-hand end of a line. This can only be
done if there is space within the pass region. If you think there should be
space for another tube but encounter problems, expand the size of the pass
region.
· Adding an extra tube line. This is only possible when there is empty
space within the Pass Region adjacent to the selected line. Resizing the Pass
Region first may be necessary.

See also:
Tube Layout: Moving objects
Tube Layout: Other Facilities
 Tube Layout: Other Facilities
Using the right-click context menu, you can mark selected tubes as plugged
tubes or as being the subject of vibration analysis. Vibration tubes are marked
with a V. The layout diagram also shows a set of representative tubes selected
by the program for vibration analysis. These are the tubes selected in the
previous run; the same tubes will normally be selected again in the next run,
unless layout modifications are severe.
Both plugged tubes and (user-selected) vibration tubes can be un-marked so
they revert to being normal tubes.
To delete tie rods, right-click the tie rods and select Delete from the context
menu.
If you right-click the diagram well away from tubes and tie rods, a context
menu appears with printing and drawing options, such as drawing tubes as
crosses rather than circles. These facilities are also available on the
uneditable output version of the Tube Layout diagram. For more information,
see Shell&Tube: Tubesheet Layout.

See also:
Shell &Tube: Geometry
Shell &Tube: Vibration Tubes
 Bolt Data

There are a range of bolt types available with Shell & Tube Mechanical.
Bolt Stress Area is determined in accordance with the rules of the relevant
design code.
Bolt Clearance data is taken from TEMA.
Where Bolt Tensioning is required, clearances will be in accordance with
Suncor Standard 0801.
The following tables list the bolt stress areas and bolt clearances implemented
within the program.

TEMA Table D-5 (Imperial)

TEMA Table D-5M (Metric)
EN 13445 Annex G Table G.8.2 (Metric)
PD 5500 Table 3.8-2 (Metric)
CODAP (Metric)
DIN (Metric)
 Bolt Data: TEMA Table D-5 (Imperial)

Bolt Cross Bolt Radial Radial Edge

Size Sectional Spacing Distance Distance Distance
Area B Rh Rr E
inches2 inches inches inches inches

0.500 0.126 1.2500 0.8125 0.6250 0.6250

0.625 0.202 1.5000 0.9375 0.7500 0.7500
0.750 0.302 1.7500 1.1250 0.8125 0.8125
0.875 0.419 2.0625 1.2500 0.9375 0.9375

1.000 0.551 2.2500 1.3750 1.0625 1.0625

1.125 0.728 2.5000 1.5000 1.1250 1.1250
1.250 0.929 2.8125 1.7500 1.2500 1.2500
1.375 1.155 3.0625 1.8750 1.3750 1.3750
1.500 1.405 3.2500 2.0000 1.5000 1.5000
1.625 1.680 3.5000 2.1250 1.6250
1.750 1.980 3.7500 2.2500 1.7500
1.875 2.304 4.0000 2.3750 1.8750

2.000 2.652 4.2500 2.5000 2.0000

2.250 3.423 4.7500 2.7500 2.2500
2.500 4.292 5.2500 3.0625 2.3750
2.750 5.259 5.7500 3.3750 2.6250

3.000 6.324 6.2500 3.6250 2.8750

3.250 7.487 6.6250 3.7500 3.0000
3.500 8.749 7.1250 4.1250 3.2500
3.750 10.108 7.6250 4.4375 3.5000

4.000 11.566 8.1250 4.6250 3.6250

4.250 13.119 9.3700 5.4330 3.7000
4.500 14.779 10.8250 5.5900 3.9400
4.750 16.500 10.8250 5.6700 4.0500

5.000 18.400 11.8110 5.8250 4.2500

5.25 20.300 11.8110 5.9050 4.3300
5.500 22.400 11.8110 6.2200 4.7200
5.75 24.500 13.0000 6.2200 4.7200

6.000 26.800 13.0000 6.3780 4.9200

 Bolt Data: TEMA Table D-5M (Metric)
Bolt Cross Bolt Radial Radial Edge
Size Sectional Spacing Distance Distance Distance
Area B Rh Rr E
mm2 mm mm mm mm

M12 72.398 31.75 20.64 15.88 15.88

M16 138.324 44.45 28.58 20.64 20.64
M20 217.051 52.39 31.75 23.81 23.81
M22 272.419 53.98 33.34 25.40 25.40
M24 312.748 58.74 36.51 28.58 28.58
M27 413.852 63.50 38.10 29.00 29.00
M30 502.965 73.03 46.04 33.34 33.34
M36 738.015 84.14 53.97 39.69 39.69
M42 1018.218 100.00 61.91 49.21
M48 1342.959 112.71 68.26 55.56
M56 1862.725 127.00 76.20 63.50
M64 2467.150 139.70 84.14 66.68
M72 3221.775 155.58 88.90 69.85
M80 4076.831 166.69 93.66 74.61
M90 5287.085 188.91 107.95 84.14
M100 6651.528 207.96 119.06 93.66
 Bolt Data: EN 13445 Annex G Table G.8.2
(Metric)
Bolt Cross Bolt Radial Radial Edge
Size Sectional Spacing Distance Distance Distance
Area B Rh Rr E
mm2 mm mm mm mm

M10 57.95 31.750 20.640 15.880 15.880

M12 84.30 31.750 20.640 15.880 15.880
M14 115.37 38.100 24.610 18.260 18.260
M16 156.59 44.450 28.580 20.640 20.640
M18 192.36 48.420 30.165 22.225 22.225
M20 244.67 52.390 31.750 23.810 23.810
M22 303.26 53.980 33.340 25.400 25.400
M24 352.66 58.740 36.510 28.580 28.580
M27 459.58 63.500 38.100 29.000 29.000
M30 560.74 73.030 46.040 33.340 33.340
M33 693.73 78.585 50.005 36.515 36.515
M36 816.86 84.140 53.970 39.690 39.690
M39 975.91 92.070 57.940 44.450
M42 1121.02 100.000 61.910 49.210
M45 1306.12 106.355 65.085 52.385
M48 1473.22 112.710 68.260 55.560
M52 1757.91 119.855 72.230 59.530
M56 2030.02 127.000 76.200 63.500
M64 2675.90 139.700 84.140 66.680
M72 3459.66 155.580 88.900 69.850
M80 4343.96 166.690 93.660 74.610
M90 5590.70 188.910 107.950 84.140
M100 6994.52 207.960 119.060 93.660
 Bolt Data: PD 5500 Table 3.8-2 (Metric)
Bolt Cross Bolt Radial Radial Edge
Size Sectional Spacing Distance Distance Distance
Area B Rh Rr E
mm2 mm mm mm mm

M10 52.30 31.750 20.640 15.880 15.880

M12 76.25 31.750 20.640 15.880 15.880
M14 104.70 38.100 24.610 18.260 18.260
M16 144.10 44.450 28.580 20.640 20.640
M18 175.10 48.420 30.165 22.225 22.225
M20 225.20 52.390 31.750 23.810 23.810
M22 281.50 53.980 33.340 25.400 25.400
M24 324.30 58.740 36.510 28.580 28.580
M27 427.10 63.500 38.100 29.000 29.000
M30 544.00 73.030 46.040 33.340 33.340
M33 675.10 78.585 50.005 36.515 36.515
M36 820.40 84.140 53.970 39.690 39.690
M39 979.70 92.070 57.940 44.450
M42 1153.00 100.000 61.910 49.210
M45 1262.00 106.355 65.085 52.385
M48 1458.00 112.710 68.260 55.560
M52 1742.00 119.855 72.230 59.530
M56 2050.00 127.000 76.200 63.500
M64 2743.00 139.700 84.140 66.680
M70 3328.00 151.610 87.710 69.058
M72 3535.00 155.500 88.900 69.850
M76 3969.00 161.135 91.280 72.230
M82 4668.00 171.134 96.518 76.516
M90 5687.00 188.910 107.950 84.140
M95 6375.00 198.435 113.505 88.900
M100 7102.00 207.960 119.060 93.660
 Bolt Data: CODAP (Metric)
Bolt Cross Bolt Radial Radial Edge
Size Sectional Spacing Distance Distance Distance
Area B Rh Rr E
mm2 mm mm mm mm

M16 144 38 24 19
M18 175 44 26 20
M20 225 47 28 24
M22 281 51 31 26
M24 324 55 33 28
M27 427 61 37 30
M30 544 66 39 32
M33 675 72 43 34
M36 820 78 47 36
M39 980 84 50 39
M42 1150 90 53 42
M45 1340 96 57 45
M48 1540 101 60 48
M52 1830 111 66 52
M56 2150 117 70 55
M60 2490 125 76 58
M64 2860 134 80 60
M68 3250 142 86 63
M72 3670 150 90 66
M76 4110 157 93 69
M80 4570 165 98 72
M85 5190 192 103 74
M90 5850 212 113 80
M95 6550 212 115 83
M100 7290 238 125 89
M105 8060 238 135 91
M110 8880 238 138 94
M115 9730 275 142 100
M120 10600 275 144 103
M125 11600 275 148 108
M130 12500 300 150 110
M135 13500 300 158 120
M140 14600 300 158 120
M145 15700 330 162 125
M150 16800 330 162 125
 Bolt Data: DIN (Metric)
Bolt Cross Bolt Radial Radial Edge
Size Sectional Spacing Distance Distance Distance
Area B Rh Rr E
mm2 mm mm mm mm

M16 157 38 24 19
M18 192 44 26 20
M20 245 47 28 24
M22 303 51 31 26
M24 353 55 33 28
M27 459 61 37 30
M30 561 66 39 32
M33 694 72 43 34
M36 817 78 47 36
M39 976 84 50 39
M42 1120 90 53 42
M45 1306 96 57 45
M48 1473 101 60 48
M52 1757 111 66 52
M56 2030 117 70 55
M60 2362 125 76 58
M64 2676 134 80 60
M68 3055 142 86 63
M72 3460 150 90 66
M76 3889 157 93 69
M80 4344 165 98 72
M85 5190 192 103 74
M90 5850 212 113 80
M95 6550 212 115 83
M100 7290 238 125 89
M105 8060 238 135 91
M110 8880 238 138 94
M115 9730 275 142 100
M120 10600 275 144 103
M125 11600 275 148 108
M130 12500 300 150 110
M135 13500 300 158 120
M140 14600 300 158 120
M145 15700 330 162 125
M150 16800 330 162 125
 Bolt Data: Suncor Standard 0801
TEMA TEMA
Bolt Bolt Tensioner Radial Tensioner
Size Spacing Spacing Distance Distance
B B Rh Rh
inches inches inches inches

0.500 1.2500 2.0625 0.8125 1.3750

0.625 1.5000 2.0625 0.9375 1.3750
0.750 1.7500 2.0625 1.1250 1.3750
0.875 2.0625 2.0625 1.2500 1.3750

1.000 2.2500 2.2500 1.3750 1.3750

1.125 2.5000 2.5000 1.5000 1.8750
1.250 2.8125 2.8125 1.7500 1.8750
1.375 3.0625 3.0625 1.8750 1.8750
1.500 3.2500 3.2500 2.0000 2.2500
1.625 3.5000 3.5000 2.1250 2.2500
1.750 3.7500 3.7500 2.2500 2.2500
1.875 4.0000 4.0000 2.3750 2.7500

2.000 4.2500 4.2500 2.5000 2.7500

2.250 4.7500 4.7500 2.7500 2.7500
2.500 5.2500 5.2500 3.0625 3.3750
2.750 5.7500 5.7500 3.3750 3.3750

3.000 6.2500 6.2500 3.6250 4.6250

3.250 6.6250 6.6250 3.7500 4.6250
3.500 7.1250 7.1250 4.1250 4.6250
3.750 7.6250 7.6250 4.4375 4.6250

4.000 8.1250 8.1250 4.6250 4.6250

 HTFS, B-JAC, and Exchanger Design and Rating
HTFS (Heat Transfer and Fluid-flow Service) was set up in the 1970s to
undertake experimental research into heat transfer and fluid flow in heat
exchangers. The results of this research rapidly became embodied in
computer programs for checking (rating) and simulating the performance of
heat exchangers and then for designing them. The underlying experimental
research continued and focused on improving the proprietary heat transfer
and pressure change methods in the software.
The B-JAC company was also set up in the 70’s, producing software for heat
exchangers, with open-literature-based thermal capabilities, but with
particular strengths in mechanical design. B-JAC, with its core products
Hetran, Aerotran and Teams, became part of AspenTech in the mid 90’s.
In 2002, when HTFS became part of AspenTech as well, a major effort was
initiated to combine the products of the two organizations. The heritage HTFS
product TASC for the thermal design of shell and tube exchangers, was
combined with Hetran, and was called Tasc+. It used the user interface
common to all B-JAC programs, and a calculation engine based on TASC, but
with extended mechanical design features from B-JAC products. Similarly the
new Acol+ product for air coolers was based on the B-JAC interface and the
heritage HTFS ACOL program.
The name HTFS was changed to HTFS+ to signify the significant software
enhancement from joining the two organizations. The B-JAC product “Teams”
for mechanical design of shell and tube exchangers was incorporated directly
unto the HTFS+ product group, and work began on creating HTFS+ versions
of other heritage HTFS products, which had no B-JAC equivalent.
In 2008, the various HTFS+ products were all renamed to have more
explicitly descriptive names, and the name HTFS+ was changed to Exchanger
Design and Rating, with the abbreviation EDR.
Aspen EDR program name changes V7.0 2008
The thermal basis of all the products remains HTFS technology, and HTFS
continues to support an experimental research program aimed at continually
improving this technology. AspenTech customers with a specific interest in the
technology can read the underlying documentation, and the new Research
Reports produced each year, via the HTFS Research Network, which can be
accessed from the EDR user interface alongside all the other software
products.
 Aspen EDR Program Name Changes V7.0
(2008)

Version 2006.5 Name V7.0 Name V7.0 Name (short)*

Aspen Tasc+ Aspen Shell & Tube Exchanger Shell&Tube

Aspen Teams Aspen Shell & Tube Mechanical Shell&TubeMech

Aspen Acol+ Aspen Air C ooled Exchanger AirC ooled

Aspen FiredHeater Aspen Fired Heater FiredHeater

Aspen Plate+ Aspen Plate Exchanger Plate

* The short name is used where space is limited (for example, within the
program menus and within the help text).
 Copyright
Version Number: V7.3.2
November 2011
Copyright © 2002 - 2011 by Aspen Technology, Inc. All rights reserved.
Aspen Basic Engineering, Aspen Engineering Suite, Aspen Exchanger Design
& Rating, Aspen Plus, Aspen Properties, AspenTech, and the aspen leaf logo
are trademarks or registered trademarks of Aspen Technology, Inc.,
Burlington, MA.
All other brand and product names are trademarks or registered trademarks
of their respective companies.
This Help is intended as a guide to using AspenTech’s software. This
documentation contains AspenTech proprietary and confidential information
and may not be disclosed, used, or copied without the prior consent of
AspenTech or as set forth in the applicable license agreement. Users are
solely responsible for the proper use of the software and the application of the
results obtained.
Although AspenTech has tested the software and reviewed the
documentation, the sole warranty for the software may be found in the
applicable license agreement between AspenTech and the user. AspenTech
MAKES NO WARRANTY OR REPRESENTATION, EITHER EXPRESSED OR
IMPLIED, WITH RESPECT TO THIS DOCUMENTATION, ITS QUALITY,
PERFORMANCE, MERCHANTABILITY, OR FITNESS FOR A PARTICULAR
PURPOSE.
Aspen Technology, Inc.
200 Wheeler Road
Burlington, Massachusetts 01803-5501
USA
Phone: (781) 221-6400
Website:www.aspentech.com
 Version 2006.5
Release date: January 2008
Current Products:
· Aspen Tasc+
· Aspen Teams
· Aspen Acol+
· Aspen FiredHeater
· Aspen MUSE

Legacy Products:
Sunset Products New Product Support Will Cease for Sunset Product

TASC , Hetran Aspen Tasc+ June 30, 2008

STX Aspen Tasc+ October 31, 2008

AC OL, Aerotran Aspen Acol+ June 30, 2008

AC X Aspen Acol+ October 31, 2008

APLE Aspen Plate+ December 31, 2008

 Version 2006
Release date: January 2007
Current Products:
· Aspen Tasc+
· Aspen Teams
· Aspen Acol+
· Aspen FIHR
· Aspen MUSE

Legacy Products:
Sunset Products New Product Support Will Cease for Sunset Product

TASC , Hetran Aspen Tasc+ June 30, 2008

STX Aspen Tasc+ October 31, 2008

AC OL, Aerotran Aspen Acol+ June 30, 2008

AC X Aspen Acol+ October 31, 2008

APLE Aspen Plate+ December 31, 2008

 HYSYS EDR Conversion Utility
The converter allows you to convert HYSYS files that use the discontinued
TASC and ACOL programs so that they will use the Shell&Tube and AirCooled
models from Aspen Exchanger Design and Rating.
This converter is designed to work with Aspen HYSYS and Aspen EDR versions
2006.5, V7.0, V7.1, V7.2, and V7.3. If you have multiple versions, be sure
that one of these versions is registered. Aspen TASC 2006.5 and Aspen ACOL
2006.5 must be installed. Patches for HYSYS 2006.5 and V7.0 must be up to
date.
To use the converter:
1 Access the Aspentech support website.
2 Search for and download hysys_converter.zip.
3 Install the files for the converter in any convenient folder.
4 Run HYSYS_ConvertToEDR.exe from this folder.
5 Select the Source Drive and Folder where the converter should look for files
to convert.
6 Select the Destination Drive and Folder where the converter should write
the converted files. It will use the same filenames as the source files.
7 In the Source File list, select the file(s) to convert. You can click Select All
to select all the files. Click Convert. It will take some time as the converter
calls Aspen HYSYS and EDR to convert the files. You will be prompted when all
the files have been converted.
8 Click OK.
Notes: The converter is compatible with files saved in older versions of Aspen
HYSYS, but not with newer files. The current registered Aspen HYSYS version
must be at least as new as the version under which the files were saved in
order to use the converter.

If the source folder and destination folder are the same, the program creates
a subfolder named ConvertToEDR under the destination folder. This
prevents files being overwritten during the conversion.
 Aspen Plus EDR Conversion Utility
The converter allows you to convert Aspen Plus files that use the discontinued
Hetran, Aerotran, and TASC programs so that they will use Shell&Tube and
AirCooled from Aspen Exchanger Design and Rating. This converter is
designed to work with Aspen Plus and Aspen EDR versions 2006.5, V7.0,
V7.1, V7.2, and V7.3; if you have multiple versions, be sure that one of these
versions is registered.
Note: The converter is compatible with files saved in older versions of Aspen
Plus, but not with newer files; the registered Aspen Plus version must be at
least as new as the version the files were saved under in order to use the
converter.
To use the converter:
1 Access the AspenTech support website.
2 Search for and download aspen_converter.zip.
3 Install the files for the converter in any convenient folder.
4 Run AspenPlus_ConvertToEDR.exe from this folder.
5 At the top, select either Aspen Plus (*.bkp) or Aspen Plus (*.inp) for the
type of file to be converted.
6 In the middle section, select the Source Drive and Source Folder where the
converter should look for files to convert. Both the Aspen Plus .bkp or .inp files
and the Hetran or Aerotran .bjt files should be in this folder.
7 Select the Destination Drive and Destination Folder where the converter
should write the converted files. It will use the same filenames as the source
files, except that the extension of the .bjt files will be changed to .edr in the
converted files.
8 In the Source File list, select the file(s) to convert. You can click Select All
to select all the files. Then click Convert.
9 It will take some time as the converter calls Aspen Plus and EDR to convert
the files. At the end you will be prompted when all the files have been
converted.
10 Click OK.
Note: If Source Folder and Destination Folder are the same, the converter will
create a ConvertToEDR folder within the source folder and store the
converted files there to avoid overwriting the original files.
 Physical Property Data Import from
This menu item provides the option to import physical property data from a
pre-existing PSF (Process Simulator File) file or from a pre-existing file from
Aspen Plus or Aspen HYSYS.

Import from Aspen HYSYS

Select your preferred version of Aspen HYSYS, the *.HSC case file, and click
1
Open.
Use the Exchanger in dialog to select your preferred heat exchanger unit
2
operation and specify the number of temperature points you require.
At this stage, you have provided enough information for the properties to
3 be generated. Click OK to move onto the second stage, Import from PSF.
See steps 2-4 below.

Import from Aspen Plus

Select your preferred version of Aspen Plus, the *.bkp case file, and click
1
Open.
Use the Exchanger in dialog to select your preferred heat exchanger unit
2
operation and specify the number of temperature points you require.
At this stage, you have provided enough information for the properties to
be generated. Click Generate to write properties to a PSF file or click
3
Import to move onto the second stage, Import from PSF. See steps 2-4
below.

Import from PSF

1 Select PSF File, the *.PSF physical property data file, and click Open.
Use the Import from PSF dialog to specify how many pressure levels you
2
require and your preferred stream mapping.
Click Save HYSYS Generated PSF File if you want to save the property
3
data to a PSF file.
4 Click OK and the property data will be imported to the EDR case file.

Aspen HYSYS (Default)

This option provides compatibility with versions that are not listed. Other
versions of Aspen HYSYS can be manually registered and then accessed
through this menu item.
Please contact support for details on how to manually register and unregister
Aspen HYSYS.
Note: Condensers and reboilers imported from Aspen HYSYS or Aspen Plus
with any efficiency set to any value other than 1 will produce different results
in EDR because this sort of efficiency is not carried over to the EDR model.
See also:
Physical Property Data HYSYS
Physical Property Data Aspen Plus
 Shell&Tube Tube
The Tube screen contains the following inputs:
Number of Tubes (total)
Number of Tubes plugged
Tube Length
Tube Type
Tube Outside Diameter
Tube Wall Thickness
Wall Specification
Tube Pitch
Tube Pattern
Tube Material
Tube Surface
Tube Wall Roughness
Tube Cut Angle
 Shell&Tube Calculation Options
The Calculation Options section includes the following screens:
Calculation Options
 Shell&Tube: Application Control

The Application Control screen contains the following inputs:

Recalculate properties before run
Output all repeat messages
Storage of Recap of Designs
Generate full output
Use phase compositions
Calling program
Note that a number of these inputs do not add functionality to the program,
but remove unnecessary functionality in order to speed up calculation times,
particularly when the program is run from a process simulator.
 Shell&Tube TEMA Specification Sheet
Descriptions
Use this sheet to specify the following optional information:
Headings, which appear at the top of the TEMA specification sheet, Input
Summary results, and the Title block of the drawings. Headings are 1 to 5
lines of up to 75 characters per line. Note that only the first 40 characters of
each line appear on the drawings.
Remarks, which appear at the bottom of the specification sheet output.
 Shell&Tube Calculation Mode
The following Calculation Modes can be selected:
· Design
· Rating / checking
· Simulation
· Maximum fouling

Design
Design mode identifies one or more exchangers that will perform a thermal
duty you specify, subject to limits on the maximum pressure loss you specify
as acceptable for each stream.
In Design mode you must provide some basic information about the overall
exchanger configuration (shell and header types, baffle type etc) and about
the tubes and tube layout used. You can also specify the range of shell sizes,
tube lengths etc within which a design should be looked for. The program will
then calculate all the other geometric features such as the exchanger size,
number of passes, nozzle sizes, baffle cut etc.
The program provides a design based on either cost optimization or on
minimum area.

Rating / Checking
Checking mode answers the question "will this exchanger do this duty?”
You have to specify the exchanger geometry and the process information
defining the duty. The result of the calculation is expressed as the ratio of
actual heat transfer surface area to the required heat transfer surface area.
An area ratio above unity implies that the specified duty can be performed.
In the Process Data Input you can specify, for each stream, the flow rate and
inlet and outlet conditions (or other information such as heat load from which
they may be deduced). In a checking calculation, the heat load implied by
these parameters is taken as fixed. The inlet pressure is fixed, but the outlet
pressure of each stream is recalculated based on the predicted pressure drop
in the exchanger.

Simulation
Simulation mode answers the question "what duty will this exchanger
achieve?”
You have to specify the exchanger geometry and process information defining
a first estimate of the duty. You normally fix the exchanger and the inlet
conditions and flow rates of the hot and cold streams. The program calculates
the stream outlet conditions and hence the duty. The result of the calculation
is the ratio of actual to required heat duty.
A Standard Simulation determines the stream outlet conditions. There is also
a Generalized Simulation available, in which either the outlet conditions or
the inlet conditions or the flow rate of each stream can be revised, as
specified by the Revise for Heat Balance in the Process Input.
Note: In a Checking calculation, the three parameters (inlet/outlet/flow rate)
are fixed for each stream and the ratio of the actual surface area ratio to that
required is determined. In both Checking and Simulation, the inlet pressure is
taken as fixed and the outlet pressure is calculated.
'Conditions' at inlet and outlet refers to specific enthalpy. Fixed conditions will
also mean fixed temperature and quality (vapor mass fraction) as long as the
pressure changes are as you have anticipated.

Maximum Fouling
Maximum Fouling Mode answers the question “what is the maximum fouling
for a specific thermal duty to be obtained?”
The calculation mode is similar to Checking, but adjusts the fouling
resistance(s) to determine, if possible, the maximum values which give an
area ratio of unity. You can specify that the fouling resistance is only adjusted
on one side (hot or cold), or that both resistances on both sides are scaled or
added to.
 Shell&Tube Location of Hot Fluid
The options are:
· Program
· Shell side
· Tube side

Select whether the tube or the shell side of the exchanger contains the hot
stream.
It is strongly recommended that you specify this information in all calculation
modes.
If you are Simulating or Rating an existing exchanger, and you get this item
wrong, the program results may be of little value. If you are Designing an
exchanger, and are unsure which is the best option, try both and see which
gives the best design.
If you do omit this item, Shell&Tube will do its best to guess the most
appropriate value, and produce a warning indicating how good it thinks this
guess is.
Allocation of a stream to the shell side or tube side is influenced by factors of
safety, reliability, company practice, maintenance requirements and capital
cost.
Some general guidelines are:
Hazardous fluids should not go on the shell side of exchangers with expansion
bellows, or with P or W type rear end heads
Heavily fouling fluids go by preference on the tube side, which is much easier
to clean
Fluids that need to be in contact with expensive materials go by preference on
the tube side.
High pressure fluids go by preference on the tube side.
Fluids with a high volume flow rate go by preference on the shell side, which
offers more geometrical options to avoid excessive pressure drop than the
tube side.
 Shell&Tube Select Geometry based on this
Dimensional Standard
The options are:
· Set default
· US
· SI

The dimensional standard used for selection of vessel thicknesses, tube

lengths, nozzle sizes will vary with where the unit may be fabricated or put
into service.
In the U.S., it is typical to use 0.0625” increments for vessel thicknesses
whereas in EU 1 mm is typical. This input allows the program to select
equipment dimensions that are relevant to the equipment being designed and
built.
 Shell&Tube Calculation Method
The options are:
· Set default
· Advanced calculation method
· Standard Shell&Tube method

The Standard method, the default, is based on defining a set of shell side
enthalpy/pressure points, then determining their location, together with a
consistent set of tube side points. Corrections are made to allow for endspaces
in baffled exchangers, where shell side mass fluxes differ from those in the
standard baffle space.
The Advanced method defines a set of physical locations within the
exchanger, and calculates the state (enthalpy and pressure) of the shell side
stream and all the tube side passes at that point. Endspaces are dealt with
explicitly, and in other points of detail approximation needed in the Standard
method are avoided.
The Advanced method is available in all calculation modes, Design, Rating,
Simulation and Maximum Fouling. It is available for most shell types, the
exceptions being Kettles, Double pipes and Flooded evaporators. The
Advanced Method is the only method that can be use for some new options,
such as variable baffle pitch.
The two calculation methods will normally give very similar results, but in
exchangers where end-spaces occupy a significant fraction of the tube length,
the Advanced method is likely to give better results.
The options for convergence algorithm, tolerances and Number of iterations
are only available with the Advanced method in Shell&Tube
Other Advanced method options let the calculation grid resolution be selected,
as low, medium, high or very high. This changes the number of calculation
points. The actual number of points cannot be set explicitly. It depends on the
complexity.
 Shell&Tube Hot Side Application
The options are:
· Program
· Liquid, no phase change
· Gas, no phase change
· Condensation

These options relate to the type of Application for which the exchanger was
designed, not the duty, potentially as yet unknown, which will be found
during the current calculation.
Specification of this parameter is optional. It may help the program set
defaults for other parameters, such as the default baffle cut being vertical for
condensers and horizontal for single phase applications. It may also help
define which fluid is more likely to be on the shell side, if this is not explicitly
specified.
The Application does NOT cause any properties data to be disregarded. If you
supply two-phase properties data, then two-phase calculations will be done
wherever appropriate, regardless of what is specified as the Application
Option.
If you supply inlet and outlet qualities in the Process data, this will help a
default value of Application to be determined. Properties data, however are
not used when selecting a default for this item. If no default can be set, the
Application will remain set to Program. This is rarely a problem, other than
introducing a risk of inappropriate defaults in a few cases.
 Shell&Tube Condenser Type
The options are:
· Set default
· Normal
· Knockback reflux

Most condenser types have the vapor and condensate flow in the same
direction. The Knockback (reflux) condenser, which is often used to separate
high and low boilers with minimal subcooling, has vapor entering the bottom
of the unit with condensate falling back against the incoming vapor. With this
type of condenser, you should consider using the differential condensation
option if the program calculates the condensation curve.
 Shell&Tube Hot Side Simulation Calculation
This item indicates which parameter is to be calculated in a Simulation
calculation:
· Set default
· Outlet temperature (and quality)
· Inlet temperature (and quality)
· Flow rate

In each case, the two parameters not being calculated are taken as fixed.
The option becomes available when the main calculation mode is set to
Simulation. [In Rating and Design, all three parameters are fixed]
A conventional Simulation calculates Outlet conditions, for a specified flow
and inlet conditions, and this is usually the default. Flow rate calculation may
be appropriate when the hot fluid is condensing steam, and the inlet condition
(dew point) and outlet condition (just below the bubble point) are fixed. The
flow will adjust itself to match the heat load required by the other stream.
The Simulation option can be set independently for the hot and cold streams,
for example the hot stream may be finding the flow, and the cold stream may
be finding the outlet temperature.
Simulation calculations need starting values for all three parameters for each
stream. These are derived from the Process data, together with an estimated
heat load if necessary. It is recommended that you explicitly supply, in the
process data input, values of the two parameters you wish to fix, so there is
no uncertainty as to what these values are.
Simulations calculations to determine inlet temperature are in general less
stable, and calculations in which the inlet temperature is being found for both
streams can be inherently unstable. Trial and error calculations for one side,
using a different simulation option are recommended in such cases.
 Shell&Tube Cold Side Application
The options are:
· Program
· Liquid, no phase change
· Gas, no phase change
· Vaporization

These options relate to the type of Application for which the exchanger was
designed, not the duty, potentially as yet unknown, which will be found
during the current calculation.
Specification of this parameter is optional. It may help the program set
defaults for other parameters, such as the default baffle cut being vertical for
condensers and horizontal for single phase applications. It may also help
define which fluid is more likely to be on the shell side, if this is not explicitly
specified.
The Application does NOT cause any properties data to be disregarded. If you
supply two-phase properties data, then two-phase calculations will be done
wherever appropriate, regardless of what is specified as the Application
Option.
If you supply inlet and outlet qualities in the Process data, this will help a
default value of Application to be determined. Properties data, however are
not used when selecting a default for this item. If no default can be set, the
Application will remain set to Program. This is rarely a problem, other than
introducing a risk of inappropriate defaults in a few cases.
 Shell&Tube Vaporizer Type
The options are:
· Set default
· Flooded evaporator or kettle
· Thermosiphon
· Forced circulation
· Falling film evaporator

The vaporizer type identifies the various equipment types which each require
special design considerations.
Flooded evaporators
Flooded evaporators are typically horizontal X shells with the bottom half to
two thirds of the shell full of tubes. Liquid is evaporated and the top one third
to half of the shell is used for a vapor/liquid disengagement space. They are
often used in refrigeration loops.
Coefficients are usually lower than K shells due to the lack of recirculation
flow but higher than unbaffled E shells. These are best modeled as X shells in
Shell&Tube, although sometimes Shell&Tube will generate critical heat flux
warnings near the top of the bundle where there is full evaporation. If the
bundle is submerged then this can usually safely be ignored.
Thermosiphon
The thermosiphon can vaporize on the shell side (horizontal) or the tube side
(vertical or horizontal). The hydraulics of thermosiphon design is critical for
proper operation.
You can specify the relationship of the heat exchanger to the column and the
associated piping in the input (see Thermosiphon Piping) or the program will
select the piping arrangement and dimensions.
Forced circulation
Forced circulation can be on either shell or tube side. Here the fluid is pumped
through and an allowable pressure drop is required input. This can be for a
once through vaporizer.
Falling film evaporators
Falling film evaporation can be done only on the tube side in a vertical
position where the liquid enters the top head and flows in a continuous film
down the length of the tube. Part of the liquid is vaporized as it flows down
the tube. Normally the vapor formed also flows down the tube due to the
difference in pressure between the top head and the bottom head. This type
of vaporizer helps minimize bubble point elevation and minimizes pressure
drop.
 Shell&Tube Cold Side Simulation Calculation
This item indicates which parameter is to be calculated in a Simulation
calculation:
· Set default
· Outlet temperature (and quality)
· Inlet temperature (and quality)
· Flow rate

In each case, the two parameters not being calculated are taken as fixed.
The option becomes available when the main calculation mode is set to
Simulation. [In Rating and Design, all three parameters are fixed]
A conventional Simulation calculates Outlet conditions, for a specified flow
and inlet conditions, and this is usually the default. Flow rate calculation may
be appropriate when the hot fluid is condensing steam, and the inlet condition
(dew point) and outlet condition (just below the bubble point) are fixed. The
flow will adjust itself to match the heat load required by the other stream.
The Simulation option can be set independently for the hot and cold streams,
for example the hot stream may be finding the flow, and the cold stream may
be finding the outlet temperature.
Simulation calculations need starting values for all three parameters for each
stream. These are derived from the Process data, together with an estimated
heat load if necessary. It is recommended that you explicitly supply, in the
process data input, values of the two parameters you wish to fix, so there is
no uncertainty as to what these values are.
Simulations calculations to determine inlet temperature are in general less
stable, and calculations in which the inlet temperature is being found for both
streams can be inherently unstable. Trial and error calculations for one side,
using a different simulation option are recommended in such cases.
 Shell&Tube Thermosiphon Circuit Calculation
Set Default
Fixed flow
Find flow
You can specify what type of thermosiphon calculation you would like
performed.
“Find Flow” finds the thermosiphon stream flowrate, consistent with the
driving head of liquid and the pressure losses in the exchanger and associated
pipework.
“Fixed flow” determines the pressure losses in the exchanger and associated
pipework for a flow rate which you specify. It determines any unaccounted
pressure losses in the inlet and/or outlet lines needed to achieve a pressure
balance around the circuit.
The two options are available in Simulation mode. In all other calculation
modes, fixed flow is the only option.
With “Find Flow” any cold (thermosiphon) stream mass flowrate you specify in
the process data, either explicitly or implicitly, is taken as an initial estimate.
 Shell&Tube Fluid Name
Enter a fluid name which will appear on the TEMA specification sheet.
Each fluid name can be up to 19 characters long and can contain multiple
words.
 Shell&Tube Mass Flow Rate (total)
You should normally enter the total flow rates for the hot and cold side
streams
A flow rate may be omitted if the stream inlet and outlet conditions are
specified, and the heat load is known, either because it has been input, or it
can be deduced from the implicit heat load of the other stream.
In the special variant of Simulation, where the flowrate is to be calculated,
any value entered here is treated as an initial estimate. This type of
Simulation is used in thermosiphon reboilers, where the flowrate of the
thermosiphon stream has to be calculated, or for simulating condensing steam
where the flowrate adjusts itself to give complete condensation to liquid
water, according the heating requirements of the cold stream.
 Shell&Tube Temperature
You should normally enter both the Inlet and Outlet Temperatures of both Hot
and Cold sides.
The inlet temperature relates to the specified stream inlet pressure and the
outlet temperature relates to the outlet pressure – as specified, or defaulted.
This can be important for vacuum duties, where pressure changes can lead to
significant temperature changes.
The inlet and outlet temperatures and qualities (vapor mass fractions) are
used together to define the stream inlet and outlet conditions. It is good
practice to define both temperature and quality when both are known.
Qualities are strictly only needed for isothermally boiling or condensing
streams, since in other cases qualities can be deduced from temperatures.
Sometimes, however, a temperature can be omitted, and only a quality input.
Qualities of 0 and 1 will then indicate the bubble and dew points respectively.
Omitting the outlet temperature and specifying an outlet quality of zero can
be useful to indicate complete condensation.
For Simulation, outlet conditions may be omitted: initial values will be set up
from an estimated heat load, in order to start the calculation.
To be more exact, for any calculation, either inlet or outlet conditions may be
omitted, (neither temperature nor quality given), if the flowrate is specified,
and the heat load is known, or can be calculated for the other side, or (for
Simulation) can be estimated. It is never possible to omit both inlet and outlet
temperatures and qualities for a stream.
Some useful additional points are:
Make sure that the process data you supply is consistent with the property
data (temperatures, specific enthalpy and quality). Minor discrepancies will
normally be detected and corrected. If there is an unresolved problem in this
area, try omitting outlet temperatures – after making sure the property data
has no obvious errors.
Inlet temperatures are used to determine the default values of the
temperature range over which physical properties are calculated. [EDR
programs set up a table of properties prior to the main calculations.
Interpolating this table gives major increases in calculation speed, and
minimal accuracy loss, compared with repeated full property calculations]. If
you omit stream inlet temperatures, you should check, and probably re-
specify, the temperature range for physical properties.
For Design and Rating calculations both inlet and outlet conditions are fixed:
it is actually the underlying inlet and outlet specific enthalpies, and heat load,
that are fixed, Sometimes you may see minor differences in outlet
temperatures in the calculated results, compared to your input values,
because of the effect of pressure changes. This is only likely in low pressure
applications, for which the calculated pressure change is very different from
the initial estimate.
 Shell&Tube Vapor Mass Fraction
You may enter the mass quality (vapor mass fraction) at inlet and outlet for
each stream.
Temperatures and qualities together are used to define stream inlet and
outlet conditions. Normally temperatures alone are adequate, since qualities
can be deduced, but qualities can be vital for isothermally boiling or
condensing streams.
For more information on inputting temperatures and qualities, see Shell&Tube
Temperatures.
 Shell&Tube Operating Pressure (absolute)
You must enter the Inlet Pressure (Absolute) for both Hot and Cold sides.
It is good practice also to enter the (estimated) Outlet pressure, or the
Pressure drop.
The one exception is Thermosiphon boiling streams, where you should specify
the pressure in the column, The pressure at inlet and outlet to the exchanger
itself will be first estimated, and then calculated, allowing for pressure
changes in the inlet and outlet pipework.
Once one of the Outlet Pressure and Estimated Pressure Drop are set, the
other is calculated as the difference from the inlet pressure.
Using the (old) Standard Method in Shell&Tube, in all calculation modes, the
outlet pressure is found using calculated pressure changes in the exchanger.
Your specified outlet pressure is thus only a first estimate.
Using the new Advanced Calculation Method, there are additional options,
including fixing outlet pressure and back calculating inlet pressure, and fixing
both inlet and outlet pressures, and calculating the scaling factor for pressure
drop required to achieve this. When using these and related options, it is
important to ensure that the stream inlet and outlet pressure are as you
require.
 Shell&Tube Pressure at Liquid Surface in
Column
For a thermosiphon, you should specify the (absolute) pressure within the
column, specifically at the surface of the liquid in the column. The
thermosiphon calculation then determines the pressure at every other point
in the circuit, allowing for frictional losses and gravitational changes.
The exchanger inlet pressure you specify is treated as an approximation only.
It is adjusted during the thermosiphon calculation.
If you omit to input a value of the pressure at the liquid surface, an
approximate value is determined, based on the exchanger inlet pressure you
specify. In the thermosiphon calculation, this estimated pressure is then help
fixed, and the exchanger inlet pressure will vary, according to the
combination of gravitational increase and frictional losses in the inlet
pipework leading from the column to the exchanger. For this reason it is best
to specify the pressure at the surface in the column, rather than default it.
 Shell&Tube Heat Exchanged
You may either specify the Total Heat Exchanged (the exchanger heat load)
or can leave it to be calculated from stream inlet and outlet conditions and
flowrate.
If you specify a heat load, and flow rate and inlet and outlet conditions, there
is the risk that these may be inconsistent. Shell&Tube can handle minor
inconsistencies – and will give a message about what has been changed.
Major inconsistencies however, will lead to a fatal error, since there is most
probably a mistake in the input.
You can select the way any such inconsistencies are resolved using the input
Adjust if Over-Specified.
 Shell&Tube: Exchanger Effectiveness
The effectiveness of a (two-stream) exchanger is the exchanger heat load as
a fraction of the maximum possible heat load. The maximum possible heat
load for a given set of process inlet conditions occurs either when the hot
stream is cooled to the cold stream inlet temperature, or when the cold
stream is heated to the hot stream inlet, whichever of these gives the lower
heat load.
The input value of effectiveness is essentially an alternative way of specifying
the exchanger duty. It is not needed if the actual exchanger duty is specified.
In Simulation calculations, the input value of effectiveness, like that of
exchanger duty is simply an initial estimate.
The value for the effectiveness lies between 0 and 1. A value of 1 can
nominally only be obtained using a pure countercurrent exchanger of infinite
area. Multi-pass exchangers, even with a very large area excess, will usually
have an effectiveness well below unity.
Effectiveness is valuable as an input in Simulation if you only know the
stream flows and inlet conditions. If you need to guess outlet conditions or
exchanger duty, using an effectiveness avoids the risk of causing an error by
guessing temperatures or duties that may be physically impossible. It is
possible not to specify any outlet conditions in Simulation and the program
will make an initial guess to start off the calculation. Input of effectiveness
gives you control over the starting conditions for the Simulation.
The program output also gives the exchanger effectiveness, based on the
calculated exchanger duty. Using the output Effectiveness from one run can
provide a good initial guess for a subsequent run in which flows or inlet
conditions have changed slightly.
 Shell&Tube Adjust if Over-Specified
The Adjust if over-specified input is enabled if you specify the Heat load, the
Mass flowrate and both the Inlet and Outlet temperature (or quality). This
input allows you to specify what the program should change if the four inputs
are inconsistent. Normally, however, an appropriate default will be selected,
so this parameter can be left unset (select Program and an appropriate
default will be supplied).
The options are:
· Program
· Flowrate
· Outlet temperature
· Inlet temperature
· Heat load
The normal default is Heat Load. This will mean in Design and Rating
(Checking) modes program can work with different heat loads for each stream
– making allowance for the inconsistency and reporting the mean value in the
output.
In Simulation mode, the program calculates the heat load, and for the other
three parameters, inlet temperature, outlet temperature and mass flow, given
any two, it calculates the third. For Simulation, the default matches the value
to be calculated.
In Simulation modes, there is always a heat balance, and any inconsistencies
in the initial estimates you supply do are corrected immediately on setting up
initial values.
You could select a different option for “Adjust if Over-specified” in Simulation
mode, but this could mean that you are fixing one of the three parameters at
a value different from what you have specified.
Adjust if over-specified can potentially be needed if the over-specification is
implicit, rather than explicit. The input may then be inaccessible. This will not
be a problem if a default is being used. If, however, there is an inappropriate
value left set from a previous run, and the input is inaccessible, temporarily
provide inputs of all four process parameters to make the Adjust if over-
specified input accessible, remove the inappropriate value, then delete any of
the four process parameters which are not required.

See Also:
Process Data Cross-Checking
 Shell&Tube Estimated Pressure Drop
You can enter an estimated pressure drop for each side. This can be important
in low pressure and vacuum applications, where the outlet pressures based on
the estimated pressure drop can significantly affect simulation result of outlet
pressures. In other cases the program supplied default will probably be
acceptable.
Supplying an outlet pressure is an alternative to supplying an estimated
pressure drop. One will be calculated from the other, once the inlet pressure
(mandatory) is specified.
If you specify neither outlet pressure nor pressure drop, defaults will be
calculated using the Allowable Pressure Drop.
The exchanger inlet and outlet pressure will be used to set defaults for the
range of pressures at which physical properties are calculated. If you are
unsure of the pressure drop, a higher rather than a lower estimate may be
appropriate. If the pressure range is large, additional default pressure levels
for properties will be defaulted. [You can add more pressure levels for
properties yourself, but this is rarely necessary]
In the unusual case of a vertical exchanger with liquid down flow,
gravitational pressure increases could exceed frictional losses. The outlet
pressure would be above the inlet pressure, and the pressure change would
be negative. Negative pressure change inputs are permissible: they will lead
to a warning message, but this can be ignored if the case as described occurs.
 Shell&Tube Allowable Pressure Drop
The Allowable pressure drop is the maximum pressure loss permitted for each
side.
Although the program can supply a default in all cases, it is unwise to use this
default in Design mode – you will get a warning message if you do. The
default will be a relatively high estimate, to try to limit the dependence of the
design on the exact estimate. This will generally produce smaller Designs,
which may be inappropriate if it subsequently turns out that the pressure
drop allowable for the exchanger is less than the crude initial estimate in the
default. Always specify an appropriate Allowable pressure drop in Design.
In other calculation modes, Allowable pressure drop is an optional input. If
the calculated pressure loss is greater than the value you supply (or the
default), then you will get a warning message.
If you supply either one of the Estimated Pressure Drop and the Allowable
Pressure Drop, the other will default to the same value.
There is a subtle difference between Estimated and Allowable pressure drops.
The allowable value is the decrease in absolute pressure, making allowance
for all frictional gravitational and accelerational effects. The allowable value is
the pressure loss, which is primarily the friction term. Gravitational changes
are assumed to be reversible and so are not included in the allowable loss.
The Allowable pressure drop must always be above zero.
The Allowable pressure drop can have an important function when using the
advanced calculation method. The default option for pressure change
calculations, when using the Advanced method for Design or Rating, is to
simulate the pressure change (calculate outlet pressure from inlet) as long as
the total pressure drop is below the Allowable pressure drop. The total
pressure drop is limited to this value, and thereafter a pressure scaling
parameter is reported. This provides a way of preventing runaway pressure
decrease in calculations, when high losses give lower pressures, lower
densities and even higher losses still. Design calculations are made more
stable, and the risk of missing appropriate Designs is reduced.
 Shell&Tube Fouling Resistance
You may enter a Fouling Resistance (Fouling Factor) for each side. The default
is zero.
In the calculation mode “Maximum Fouling” the fouling resistances you
initially specify will be adjusted to determine the values that will just permit
the specified duty. You can select whether to modify one or both resistances,
under the Program Options / Thermal Analysis / Fouling.
The fouling resistance relates to the surface with which the fluid is in contact.
This means that the tube side fouling resistance should relate to the inside
surface of the tube. In the output, all heat transfer coefficients and fouling
resistances are related to a standard reference area, based on the tube outer
diameter. The tube side fouling resistance you see in the output will differ
from your input value.
For the shell side there are no issues with surface area, except for two special
cases where care needs to be taken. For lowfin tube the fouling resistance
you input should relate to the plain tube OD area. For longitudinally finned
tubes, any shell side fouling value input is the local value on tubes or fins,
and should not be referred back to the tube OD area.
The following information may also be useful.
The fouling resistance causes a reduction in calculated heat transfer, but will
not, on its own, cause allowance to be made for increased pressure drop as
foulant blocks tube side or shell side flow area. You can allow for this by
specifying foulant thickness or conductivity on the Program Options / Thermal
Analysis / Fouling tab.
All fouling resistances are uncertain, and are likely to increase with time. At
the bottom of the output Thermal Hydraulic Summary / Performance there is
a diagram showing the average value of the relative contributions to the
overall thermal resistance of shell side and tube side heat transfer (clean),
fouling resistances and the tube wall. If either or both fouling resistances
dominate, you should stop to ask whether the fouling resistances you have
input are appropriate.
If you specify large fouling resistances in Design mode, the exchanger will
need to correspondingly increase in size, to give the heat transfer area
needed. This will reduce fluid velocities, and lead to conditions where, in
practice, fouling is more likely to occur. Large fouling resistances in Design
can become a self-fulfilling prophecy.

See also:
TEMA Fouling Resistances
 Physical Property Data User Specified
Properties with Heat Load
This option is the same as for the normal User Specified Properties, with three
exceptions:
· Heat Loads are supplied instead of specific enthalpies
· A reference mass flow must be supplied (on the Compositions input form)
· Properties data with heat loads may only be supplied at a single pressure
level
The heat load may be defined in either increasing or decreasing terms. This
will be corrected internally to give a specific enthalpy that increases with
temperature.
Note that for single phase substances (excluding reacting fluids or
electrolytes), it is not necessary to provide either specific enthalpy or heat
load. The program will construct values internally by integrating specific
heats. Whenever specific enthalpies are available, however, it is
recommended that they be provided as input.
 Physical Property Data Non-Newtonian Fluids
Newtonian fluids have the relation between local shear stress and shear rate
(gradient, transverse to the flow direction, of the local velocity) which defines
the viscosity.

For a power law Non-Newtonian fluid, the relation is

This means that effective viscosity is a function of shear rate.

If n is unity, the fluid is Newtonian.

If n is above unity, the fluid is shear-thickening (pseudoplastic).
If n is below unity, the fluid is shear-thinning (dilatant).

To specify a non-Newtonian fluid, you need to supply the shear rate exponent
n, the parameter K, in addition to (effective) viscosity.
The Parameter K can vary with temperature quite significantly (like viscosity).
Variation of n with temperature is usually small.
Currently, the Aspen Plate program uses the non-Newtonian physical property
information in thermal-hydraulic calculations. Few data have been published
for PHE's using non-Newtonian fluids, so results from the program should be
treated with caution.

Notation
Consistency coefficient

Power index

Viscosity Ns/m²

Shear stress rate 1/s

Shear stress Pa
See also:
Non-Newtonian Fluids - Data Input
 Physical Property Data Aspen Properties -
Composition
The composition specification determines how mixture physical properties are
calculated.
Aspen Component Table
The Aspen Component Name column contains the name of the component.
The input for the Composition column can be specified as fractions,
percentages, or actual flowrates. The table of compositions will always be
normalized to determine the actual fraction of each component.
The Aspen Formula column contains the databank formula for the component.
Search Databank
The Search Databank button must be used to select components from the
Aspen Properties Databank. When components are selected, they will appear
in the Component name formula list. If Aspen Properties is to be used for
more than 1 stream, it is recommended that you select all the components for
all the streams. All the components will then appear for each stream that is
using Aspen Properties and the composition inputs will dictate whether the
component is present in the stream.
Delete Row
Delete Row can be used to remove a component from the list.
 Physical Property Data Aspen Properties -
Property Methods
The Property Methods screen includes the following inputs:
Aspen Property Method
Aspen Free-Water Method
Aspen Water Solubility
Aspen Flash Option
 Physical Property Data Aspen Properties -
Advanced Options
The Advanced Options screen includes the following options:
Select components locally
This option allows the user to use the Search Databank button to select
components to be added to the component list. The component data will be
stored in the EDR file and an external Aspen Properties file will not be
required.
Import Existing Aspen Properties file
This option allows users to import an existing APRBKP file and store it in the
EDR file. Once imported, the external file is no longer needed and users can
then treat the information as if it had been specified locally.
Reference external Aspen Properties APRPDF or Aspen Plus APPDF file
This option allows users to use existing Aspen Properties or Aspen Plus files
which have property package information already established. This
information cannot be stored in the EDR file so these reference files must
accompany the EDR file wherever it is to be run.
 Physical Property Data COMThermo -
Composition
The composition specification determines how mixture physical properties are
calculated.
COMThermo Components Table
The COMThermo Component Name column contains the name of the
component.
The input for the Composition column can be specified as fractions,
percentages, or actual flowrates. The table of compositions will always be
normalized to determine the actual fraction of each component.
The Components ID
The COMThermo Component ID is an internal reference number used by
COMThermo to identify the component
Search Databank
The Search Databank button must be used to select components from the
COMThermo Databank. When components are selected, they will appear in
the Component name formula list.
Delete Row
Delete Row can be used to remove a component from the list.
 Physical Property Data COMThermo - Property
Methods
None
Ideal-Ideal
Ideal-Ideal/LK
NRTL-Ideal
NRTL-Ideal/LK
Peng-Robinson
Peng-Robinson/LK
PRSV
PRSV/LK
SRK
SRK/LV

Based on the Property Package selected a Vapor Model and Liquid Model will
be displayed.
 Physical Property Data COMThermo -
Interaction Parameters
Interaction Parameters used in COMThermo are viewable via a selection tree
on the Property Package screen, when the Advanced Views tick box is
checked.
You must have selected either a PR (Peng Robinson) or SRK (Soave Redlich
Kwong) based VLE method, and have defined a set of components.
You are advised against editing the interaction parameters, unless you have
specialist expertise.
 Physical Property Data B-JAC - Composition
The composition specification determines how mixture physical properties are
calculated.
B-JAC Components Table
The B-JAC Component Name column contains the name of the component.
The input for the Composition column can be specified as fractions,
percentages, or actual flowrates. The table of compositions will always be
normalized to determine the actual fraction of each component.
The Component Type
The Component type input allows the user to define explicitly those
components that he wants the program to treat as a condensable or a non-
condensable. If not selected, the program will determine this.
Search Databank
The Search Databank button must be used to select components from the B-
JAC Databank. When components are selected, they will appear in the
Component name formula list.
Delete Row
Delete Row can be used to remove a component from the list.
Insert Row
Insert Row can be used to insert a new row into the list.
 Physical Property Data B-JAC - Property
Methods
The Property Methods screen includes the following inputs:
BJAC VLE Calculation Type
BJAC VLE Calculation Method
 Physical Property Data B-JAC - Interaction
Parameters
You are advised against editing the interaction parameters, unless you have
specialist expertise
 Physical Property Data B-JAC - NRTL
The NRTL method requires binary interaction parameters for each pair of
components and an additional Alpha parameter. This data is not available
from the databank.
 Physical Property Data B-JAC - Uniquac
The Uniquac method requires binary interaction parameters for each pair of
components and also needs a surface parameter and volume parameter. This
data is not available from the databank.
 Physical Property Data Properties - Pressure
Levels
Each set of stream properties data is all defined at a single pressure level. You
may however supply repeated sets of data at more than one pressure level if
you wish. This is lets the pressure dependence of properties data be
calculated.
Data at two pressure levels are usually adequate to define pressure
dependence, although more levels can be defined if desired. The pressure
levels might typically correspond to the highest and lowest pressure levels
present in the equipment being modeled, typically the inlet and outlet
pressures, however this is not a rigorous requirement. Any pressure levels
not too far from the mean stream pressure in the exchanger can be used.
Data will be interpolated or extrapolated with respect to pressure as required.
If you supply data at two pressures, it is sensible for these pressures to differ
by at least a few percent, even if the exchanger inlet and outlet pressures are
closer than this [and if they are closer than this, you probably do not need to
allow for pressure dependence in any case].
Pressure dependence of liquid and vapor properties data is in most cases less
important than of T-h-x data. Such dependence is only modeled fully if such
data are supplied at more than one pressure level. The exception is vapor
density, for which pressure dependence is allowed for whenever T-h-x
pressure dependence is allowed for.
If you supply data at more than one pressure level, then any T-h-x data
should be defined in terms of specific enthalpies with a consistent zero, rather
than heat loads.
The temperature ranges over which data are supplied need not exactly match
at all the pressure levels.
If data are supplied for two phases at one pressure level, then they should
normally be supplied for two phases at all pressure levels for that stream.
This can be achieved by expanding (or reducing) the temperature range over
which data are supplied.
If data are supplied at three or more pressure levels for any stream, then
these pressures must either be in increasing or decreasing order, within the
program input file, [and as displayed in the User Interface].
 Physical Property Data Non-Newtonian Fluids -
Data Input
Single phase liquid streams can be specified as being non-Newtonian by
setting the Physical Property Package to User Specified Properties.
The non-Newtonian parameters, shear rate exponent n, and parameter K can
then be entered in the Stream Properties table. Values of viscosity then
become effective viscosity as defined in non-Newtonian fluids.
 Shell&Tube Geometry
The Geometry screen contains the following inputs:
Front Head Type
Shell Type
Rear Head Type
Exchanger Position

Shell(s) - ID
Shell(s) - OD
Shell(s) - Series
Shell(s) - Parallel

Tubes - Number
Tubes - Length
Tubes - OD
Tubes - Thickness

Tube Layout - `Option'

Tube Layout - Tubes (Number off)
Tube Layout - Tube Passes
Tube Layout - Pitch
Tube Layout - Pattern

Baffles - Spacing (centre-centre)

Baffles - Spacing at Inlet
Baffles - Number
Baffles - Spacing at Outlet
Baffles - Type
Baffles - Tubes in Window
Baffles - Orientation
Baffles - Cut (%d)
 Shell&Tube Tube Layout
The Tube Layout screen becomes available when the Tube Layout Option is
set to Use Existing Layout. This screen can be used to edit an existing
layout.
The Tube Bundle Layout facility is available with all calculation modes except
for Design. This includes all thermal checking or simulation calculation modes,
in which it is important to specify the geometry of an exchanger.
When you first run a case, by default it generates and displays a Tube Layout
Diagram, based on basic input data items which you have provided or which
are defaulted, for example to TEMA recommended values.
After running, you can see the Tube Layout diagram under the Results
section.

For subsequent runs, you can select, within the Geometry Summary or
Bundle Layout sections of the input, to either:
Use Existing Layout - Enables the tab Tube Layout, so the existing tube
layout drawing can be edited.
New (optimum) layout - Results in a new layout being created from scratch
next time Shell&Tube is run, using the main geometry input specified. This
option is always used in Design mode.
New, match Pass Details - this lets you specify the number of rows and
columns in each tube pass, so you can achieve an exact (or very close) match
to an existing tube layout when the layout is calculated.
New, match tube count (obsolete) – This is a cruder method of matching
an existing exchanger. It determines an optimum layout, then (within
sensible limits) removes tubes until the specified tubecount. It does nothing if
you specify a larger count than in the optimum layout.

Use Existing Layout can be used to adjust the detail of a previously

calculated layout. This may involve adding or removing tubes, or it may
involve selecting tubes as vibration tubes or explicity marking tubes as
plugged tubes.

Note: The term Tube Layout is used as shorthand for Tube Bundle Layout.
The local arrangement of tubes with respect to each other and the flow
direction is the Tube Pattern of 30, 45, 60, or 90 degrees.
The objects in the Tube Layout include
 · Bundle Limits
· Pass Regions
· Nozzles
· Baffles
· Tie Rods
· Tube Lines
· Impingement Plate
· Impingement Rods
· Sealing Strips
· PP Lane Sealing Strips
· Plugged tubes
· Vibration tubes
· Bundle Runners
· Longitudinal Baffles
After the initial run you can refine the tube layout diagram.
Changing the detail of the tube layout often has relatively little effect on the
calculated exchanger performance. The most important parameter is likely to
be the number of tubes. If you are modeling an existing layout, you should
input this parameter directly, so it is used even if the calculated layout
predicts a slightly different number.
If you make very substantial modifications to the tube layout, for example by
changing the relative locations of various passes, then you might possibly
cause warnings or even fatal errors when the case is subsequently run. You
can avoid this by running using data from the main input only, so the detail of
your current layout is not taken into account.
See also:
Specifying details of each pass
Tube Layout Overview
Vibration Tubes
Plugged Tubes
 Shell&Tube Shell/Heads
The Shells/Heads screen contains the following inputs:
Front Head Type
Shell Type
Rear Head Type
Exchanger Position
Location of Front Head for Vertical Units
"E" shell flow direction (inlet nozzle location)
Double Pipe or Hairpin unit Shell Pitch
Tube Side Inlet at Front Head
Flow within Multi-tube Hairpin (M-shell)
Overall flow for Multiple Shells

Shell(s) - ID
Shell(s) - OD
Shell(s) - Thickness
Shell(s) - Series
Shell(s) - Parallel

Front Head - ID
Front Head - Thickness

Rear Head - ID
Rear Head - Thickness

Kettle - ID
Kettle - OD
 Shell&Tube Covers
The Covers screen contains the following inputs:
Front Cover Type
Front Cover Welded to a Cylinder

Rear Cover Type

Rear Cover welded to a Cylinder

Shell Cover Type

Distance from U-bend centre to shell cover

 Shell&Tube Tubesheets

The Tubesheets screen contains the following inputs:

Tubesheet Type
Front Tubesheet Thickness
Rear Tubesheet Thickness

Tube to Tubesheet Joint

Tube Projection from Front Tubesheet
Tube Projection from Rear Tubesheet

Include Expansion Joint

 Shell&Tube Flanges
The Flanges screen contains the following inputs:
Flange Type - Hot Side
Flange Type - Cold Side
 Shell&Tube Low Fins
The Lowfins screen becomes available when the Tube Type ‘Lowfin tube’ is
selected

For a lowfin tube, you can either select a standard tube from the lowfin tube
databank, or specify the geometry yourself.

The Lowfin Tube screen contains the following inputs:

Tube Outside Diameter
Tube Wall Thickness
Fin Density
Tube Wall Thickness under Fin
Tube Root Diameter
Fin Height
Fin Thickness
Outside/Inside Surface Area Ratio
Lowfin Manufacturer
Lowfin Catalogue Number
Distance Unfinned at Baffle

Whether or not you specify that a lowfin tube is from a databank, you can
specify the Distance Unfinned at Baffle.
 Shell&Tube Longitudinal Fins
The Longitudinal Fins screen becomes available when the Tube Type
‘Longitudinal Fin’ is selected, and it contains the following inputs:
Longitudinal Fins per Tube
Longitudinal Fin Height
Longitudinal Fin Thickness
Longitudinal Root Spacing
Longitudinal Fin Cut and Twist Length
 Shell&Tube Inserts
The Inserts screen contains the following inputs:
Tube Inserts
Tube Insert Type

Twisted Tape 360 degree Twist Pitch

Twisted Tape Thickness

Tube Insert Core Outside Diameter

Tube Insert Wire Outside Diameter

hiTRAN Wire Loop Inserts

hiTRAN Insert Calculation Type
hiTRAN Part No.
hiTRAN Part No. (previous)
Note: To run a case using hiTRAN Wire Loop Inserts you must first purchase
and install an additional software component from CalGavin.
 Shell&Tube KHT (Brown Fintube) Twisted Tubes
The KHT Twisted Tubes screen contains the following inputs:
Twisted Tube twist pitch

Shell Type: within Shroud (convert to)

Shell Type: Nozzle Layout (convert from)
Shroud Inlet Location
Shroud Inlet Gap Length
Shroud Outlet Gap Length
Shroud Thickness
Skid Bar Angle (degrees)
Note: To run a case using Twisted Tubes you must first purchase and install
an additional software component from Koch Heat Transfer (KHT).
 Shell&Tube: Internal Enhancement
The Internal Enhancement screen contains the following inputs:
Tube Internal Enhancement
Tube Outside Diameter
Tube Wall Thickness
Internal surface area per unit length
Sieder-Tate coefficient: STC
Coefficient for Darcy fiction factor: C
Exponent for Darcy fiction factor: D
 Shell&Tube Baffles
The Baffles screen contains the following inputs:
Baffle Type
Tubes are in Baffle Window
Baffle Cut (% diameter) inner/outer/intermediate
Align Baffle Cut with Tubes
Multi-Segmental Baffle starting Baffle
Baffle Cut Orientation
Baffle Thickness

Baffle Spacing Center-Center

Baffle Spacing at Inlet
Baffle Spacing at Outlet
Number of Baffles

End Length at Front Head (tube end to closest baffle)

End Length at Rear Head (tube end to closest baffle)

Distance between baffles at central inlet/outlet for G, H, I, J shells

Distance between Baffles at Center of H shell

Baffle OD to Shell ID diametric clearance

Baffle Tube Hole to Tube OD diametric clearance
 Shell&Tube Tube Supports
The Tube Supports screen contains the following inputs:
Special Inlet Nozzle Support
Support or Blanking Baffle at Rear End
Length of Tube beyond Support/Blanking Baffle
Support/Baffle to tangent of U-bend distance

Number of Extra Supports for U-bends

Number of Supports at center of H shell
Number of Supports at Inlet/Outlet for G, H, I, J Shells
Number of Supports at K, X Shells

Number of Supports between Central Baffles

Number of Supports at Front Head End Space
Number of Supports at Rear Head End Space
 Shell&Tube Longitudinal Baffles
The Longitudinal Baffles screen becomes available if a Shell Type of ‘F, G or H’
is selected.
It contains the following inputs:
Window Length at Rear Head for F, G, H Shells
Window Length at Front Head for G, H Shells
Window Length at Center for H Shells
Baffle Thickness
Longitudinal Baffle to Bundle Clearance
 Shell&Tube Variable Baffle Pitch
The Variable Baffle Pitch screen contains the following inputs:
Number of Regions for Variable Baffle Pitch
Number of Baffle Spaces
Baffle Spacing
Baffle Cut Percent, Outer
Baffle Cut Percent, Inner

See also:
General advice on Variable Baffle Pitches
 Shell&Tube Deresonating Baffles
The Deresonating Baffles screen contains the following inputs:
Number of Deresonating Baffles
Largest Deresonating Baffle-Baffle or Baffle-Shell Distance

You can explicitly specify the number and location of Deresonating baffles,
which can protect against any acoustic resonance, one of the conditions
reported in the vibration output.
According to Handbook Sheet VP4, deresonating baffles are often placed so
that they divide the shell diameter into about one third and two thirds with
the objective of preventing the fundamental frequency wave and its first
harmonic from occurring. Dividing the shell diameter into two parts would
only prevent the fundamental frequency wave.
These baffles do not appear on the tube layout output, but are handled fully
in the internal calculations. If tubes need to be removed to make space for
these baffles, you can simply specify the remaining number of tubes in the
input.
 Shell&Tube Layout Parameters
The Layout Parameters screen contains the following inputs:
Tube Layout option
Number of Tubes (total)
Tubes in Layout
Main input/Tube Layout inconsistencies
Tube Layout Design
Tube Pattern
Tube Pitch
Tube Passes
Pass Layout
Pass Layout Orientation
Tube Layout Symmetry
Bundle Limit Symmetry
Number of Sealing Strip Pairs
Sealing Strip Orientation
Orientation of U-bends
 Shell&Tube Layout Limits/Pass Lanes
The Layout Limits/Pass Lanes screen contains the following inputs:

Open Space between Shell Inside Diameter and Outermost Tube

Open distance at Top of Layout
Open distance at Bottom of Layout
Open distance on Left Side of Layout
Open distance on Right Side of Layout
Shell ID to Outer Tube Limit Diametric Clearance
Outer Tube Limit Diameter

Pass Partition Lanes

Horizontal Pass Partition Width
Vertical Pass Partition Width
Minimum U-Bend Diameter
Number of Horizontal Pass Partition Lanes
Number of Vertical Pass Partition Lanes

Cleaning Lane or Tube Alignment

 Shell&Tube Tie Rods/Spacers
The Tie Rods/Spacers screen contains the following inputs:
Number of Tie Rods
Tie Rod Diameter
Spacer Diameter
Replace Tubes by Tie Rods if necessary
 Shell&Tube: Pass Details
For the Pass Details input, a table of values can be specified for each Pass
Region. Each pass region has a number determining where in the layout it
occurs. This number will in general be different from the conventional Pass
number, which is determined by the sequence of tube side flow.
With the Standard (horizontal) Pass Layout Orientation, pass regions are
numbered from the top and in any band two pass regions, from left to right.
The alternative Pass Layout Orientation (Vertical) is generated by flipping the
standard orientation about a diagonal line between top right and bottom left.
Pass Region one, instead of being at the top of the exchanger, is on the right
hand side.
The vertical Pass Layout Orientation is generated from the Standard
(horizontal) orientation by interchanging the X-axis (horizontal) and Y-axis
(vertical) through the center of the bundle. Note that this is not the same as
rotating the axes.
The following inputs are available for each pass region:
Flow Pass Number
Number of Tube Rows
Number of Tube Columns
Number of Tubes
Number of Plugged Tubes
Tube in Reference Location

See also:
Tube Layout: Overview
Tube Bundle Layout: How it is Calculated
Bundle Layout
Number of Tubes - all regions
Number of Tubes plugged
 Shell&Tube Shell Side Nozzles
The Shell Side Nozzles screen contains the following inputs:
Use separate Outlet Nozzles for Hot/Cold side Liquid/Vapor flows
Use the specified Nozzle dimensions in `Design' mode
Nominal Pipe Size
Nominal Diameter / Actual OD / Actual ID
Wall Thickness
Nozzle Orientation
Distance to Front Tubesheet
Number of Nozzles
Multiple Nozzle Spacing
Nozzle / Impingement Type
Remove Tubes below Nozzle

Maximum Nozzle RhoV2

Shell Side Nozzle Flange Rating

Shell Side Nozzle Flange Type
Shell Side Nozzle Location options

Location of Nozzle at U-Bend

Nozzle Diameter displayed on TEMA sheet

 Shell&Tube Tube Side Nozzles
The Tube Side Nozzles screen contains the following inputs:
Use separate Outlet Nozzles for Hot/Cold side Liquid/Vapor flows
Use the specified Nozzle dimensions in `Design' mode
Nominal Pipe Size
Nominal Diameter / Actual OD / Actual ID
Wall Thickness
Nozzle Orientation
Distance to Tubesheet
Centerline offset distance
Maximum Nozzle RhoV2
Tube Side Nozzle Flange Rating
Tube Side Nozzle Flange Type
 Shell&Tube Domes/Belts
The Domes/Belts screen contains the following inputs:
Dome OD
Dome ID

Vapor Belt Diametric Clearance

Vapor Belt Slot Area
Vapor Belt Axial Length
 Shell&Tube Impingement
The Impingement screen contains the following inputs:
Impingement Protection Device

Impingement Plate
Impingement Plate Diameter
Impingement Plate Length (parallel to tube axis)
Impingement Plate Width (normal to tube axis)
Impingement Plate Thickness
Impingement Plate Distance in from Shell ID
Impingement Plate clearance to Tube Edge
Impingement Plate Perforated Area %

Impingement Rods
Rows of Impingement Rods
Impingement Rod Layout
Impingement Rod Diameter

Note: Before specifying the details of any impingement device, you should
set Yes, Impingement for the input Nozzle / Impingement type for the
shell side inlet nozzle.
 Shell&Tube Thermosiphon Piping
The Thermosiphon Piping screen contains the following inputs:
Pipework Loss Calculation
Percent Head Loss in Inlet Pipe
Percent Head Loss in Outlet Pipe
Height of Column Liquid Level
Height of Heat Transfer Region Inlet
Height of Return Line to Column

See also:
Thermosiphons
 Shell&Tube Inlet Piping Elements
The Thermosiphon Inlet Piping Elements screen contains the following inputs:
Inlet Circuit Element
Internal Diameter
Length (pipe) or Radius (arc)
Velocity Heads (general element)
Elements in Series
Elements in Parallel
 Shell&Tube Outlet Piping Elements

The Thermosiphon Inlet Piping Elements screen contains the following inputs:
Outlet Circuit Element
Internal Diameter
Length (pipe) or Radius (arc)
Velocity Heads (general element)
Elements in Series
Elements in Parallel
 Shell&Tube Thermosiphons
In a thermosiphon, the flow of the (boiling) thermosiphon stream is
determined by a driving head of liquid, at the bottom of a column (or other
vessel) to which the exchanger is attached.
Thermosiphon reboilers can have the boiling stream on the shell side or tube
side, have horizontal or vertical shells, and have any shell type (except K-
shells). In practice, a limited range of option is used, but there are no
restrictions on what the program can handle.
Thermosiphon reboilers can be selected in all calculation modes. There is a
range of calculation types for reboiler which can depend on the calculation
mode. Fundamental issues are how the pipework losses are determined and
whether the thermosiphon flow is fixed or modified to give a pressure balance
around the thermosiphon circuit
If the heating stream is condensing (as it usually is), its flowrate is usually
adjusted to give complete condensation (See Thermosiphon Hot Stream
Flow).
When it has calculated the exchanger flowrates and thermal performance, the
program performs a stability assessment on the thermosiphon circuit.

See also:
Thermosiphon Type (calculation modes)
Height of Column Liquid Level
Height of Heat Transfer Region Inlet
Height of Return Line to Column
Designing Thermosiphon Reboilers
 Shell&Tube Vessel Materials
Use this sheet to select the material of construction for these items:
Cylinder - hot side
Select a generic material, for the hot side components. The list includes all
items except tubesheets, tubes, and baffles.
Cylinder - cold side
Select a generic material, for the cold side components. The list includes all
items except tubesheets, tubes, and baffles.
Tubesheet
Select a generic material for the tubesheet(s).
Double tubesheet (inner)
Select a generic material, for the inner tubesheet(s).
Baffles
Select a generic material for the baffles, which are generally of the same
material type as the shell cylinder.
Tubes
Select a generic material for the tubes.
For all items the default is carbon steel. To specify a material grade, click the
Databank Search button.
If you specify a material designator for the tube material, the program
retrieves the thermal conductivity of the tube from its built-in databank.
However, if you have a tube material that is not in the databank, you can
specify the thermal conductivity of the tube material on the Tube Properties
tab.

Databank search (appendix)

 Shell&Tube Cladding/Gasket Materials
Use this sheet to select the generic material for cladding, if required, on the
Hot side or Cold Side of the tubesheet and to specify the gasket type.
To specify a specific material grade for the hot/cold side gaskets, click the
Databank Search button.
The program asks for gasket materials on both sides; although in the case of
a fixed tubesheet type heat exchanger, there will be gaskets on only one side.
If you do not specify a value, the program uses compressed fiber as the
material for the mechanical design and cost estimate. The heat exchanger
specification sheet will not show a gasket material, if unspecified.

Databank search (appendix)

 Shell&Tube Tube Properties
Use this sheet to specify Tube Properties if the required properties are
different to those listed in the Material Database for the selected material
type or specification.
 Shell&Tube Design Specifications
The Design Specification screen contains the following inputs:

Codes and Standards

Design Code
Service Class
TEMA Class
Material Standard
Dimensional Standard

Design Conditions
Design Pressure (gauge)
Design Temperature
Vacuum Design Pressure (gauge)
Test Pressure (gauge)
Corrosion Allowance
Radiography
 Shell&Tube Geometry Options
The Geometry Options screen contains the following inputs:

Geometry Options
Use Shell ID or OD as reference
Shell Side Nozzle Location options
Location of Nozzle at U-bend
Allow Baffles under Nozzle
Use Proportional Baffle Cut
Number of Rows between Sealing Strips
Percent of Tubes to be Plugged

Shell Disengagement Option

Remove Tubes for Vapor Disengagement Space in Flooded Evaporator
Percent of Shell Diameter for Disengagement

Variable Baffle Pitch Options

Number of Regions for Variable Baffle Pitch
Variable Baffle Pitch, First to Last Pitch Ratio
 Shell&Tube Geometry Limits
Use this sheet to specify limits for the program to work within when
performing a Design calculation.
Shell Diameter Limits
Tube Length Limits
Tube Passes Limits
Baffle Spacing Limits
Baffle Cut Limits
Shells in Series and Parallel
Use Pipe for Shells below this Diameter
 Shell&Tube Process Limits
Use this sheet to specify limits for the program to work within when
performing a Design calculation.
Velocity Limits
Target Pressure Drop in Nozzles
Maximum Entrainment Ratio
Allow Local Temperature Crosses
 Shell&Tube Optimisation Options
The following optimization options give you control over the Design
Optimization and the cases it reports. Default values should be adequate in
most cases.
Design Search Thoroughness options
Basis for Design Optimization
Highest Cost or Area Ratio Considered
Minimum Percent Excess Surface Area Required
Show Units that meet Minimum Actual/Required Surface Area Ratio
Show Units that meet Maximum Actual/Allowed Hot Side Pressure Drop Ratio
Show Units that meet Maximum Actual/Allowed Cold Side Pressure Drop Ratio
Number of Designs before Option to Stop
 Shell&Tube Heat Transfer
The Heat Transfer screen contains the following inputs:
Heat Transfer Coefficient
Heat Transfer Coefficient Multiplier
U-bend Area used for Heat Transfer
Fraction of Tube Area submerged for Shell Side Condensers
Weir Height above Bundle for Kettle Reboilers
 Shell&Tube Pressure Drop
The Heat Transfer screen contains the following inputs:
Pressure Drop Multiplier
Falling Film Evaporator Distributor Velocity Heads for Pressure Loss
Calculation
 Shell&Tube Delta T
The Delta T screen contains the following inputs:

Temperature Difference options

Minimum Allowable MTD Ft Correction Factor
 Shell&Tube Fouling
The Fouling screen contains the following inputs:

Fouling Calculations
Fouling Calculation Options
Fouling Layer Thickness
Fouling Thermal Conductivity
 Shell&Tube General
The Methods/Correlations - General screen contains the following inputs:

Pressure Drop Options

Hot Side Pressure Drop Calculation Options
Cold Side Pressure Drop Calculation Options

Vibration Analysis Options

Vibration Analysis Method
Tube Axial Stress
Effective Cross Flow Fraction

Single Phase Tube Side Heat Transfer Method

Low Fin Tube Calculation Method
Viscosity Method for Two Liquid Phases
 Shell&Tube Condensation
The Methods/Correlations - Condensation screen contains the following
inputs:

Condensation Options
Desuperheating Heat Transfer Method
Condensation Heat Transfer Model
Vapor Shear Heat Transfer Enhancement
Liquid Subcooling Heat Transfer/Vertical
Priority for Condenser Outlet Temperature (mixtures)
 Shell&Tube Vaporization
The Vaporization screen contains inputs for:
Vaporization Options
Subcooled Boiling accounted for in
Post Dryout Heat Transfer determined

Boiling Curve Correction

Heat Flux Reference Point
Temperature Difference (Delta T) Reference Point
Boiling Curve Exponent on Delta T
Correction to Boiling Curve

Falling Film Evaporation Method

See Also:
User-specified Boiling Curve
 Shell&Tube Enhancement Data
Calculations on exchangers with some form of enhancement not explicitly
modeled by Shell&Tube can be performed if you can supply Performance Data
(Friction Factors and Colburn Factors) from which Shell&Tube can calculate
pressure losses and heat transfer coefficients.
This is most likely to be useful for tube side enhancements, such as tube
inserts, but it can also be used for axial shell side flows. Such Performance
Data relate to single phase streams. Use for two-phase streams is not
recommended.
For shell side and/or tube side:
· Select Enhancement
· Enter an identification for the Enhancement
Enter sets of:
· Reynolds Numbers
· Colburn Factor
· Friction Factor
You should not specify performance data for enhanced surfaces such a Twisted
Tape Inserts for which Shell&Tube already contains methods.

Reynolds Numbers
A list of Reynolds Numbers is used as part of the Shell&Tube performance
data table.
The Reynolds Numbers should cover the range of values expected. This can be
estimated by running an initial Shell&Tube case without performance data.
You can provide data up to 16 Reynolds Numbers, but fewer are often
adequate. The Reynolds Numbers may be in any order, but no two should be
the same. Regions of laminar, transitional and turbulent flow can therefore be
defined in the table. Shell&Tube will interpolate the data on a log-log basis. It
will also extrapolate, but this is less reliable.
Shell&Tube uses the supplied data in the form of:
Re = [mass flux]*[hydraulic diameter] / [viscosity]
Where the mass flux and hydraulic diameter are based on an empty tube or
channel (for tube side flow the hydraulic diameter is the tube inside
diameter). For shell side flow it is that for axial flow within the bundle.
Colburn Factor
For each Reynolds Number in a Shell&Tube performance data table, you input
an associated heat transfer factor (currently the Colburn j factor). Shell&Tube
uses the supplied data to calculate the local heat transfer coefficient in the
form of:
heat transfer coefficient = Cj * [mass flux]*[specific heat]*[Prandtl
Number]^-2/3
Where the mass flux is based on an empty tube or channel. For shell side flow
it is that for axial flow within the bundle.
The relation used to generate the Colburn Factor data is assumed to be
dependent only on Reynolds Number, not Prandtl Number. If your Cj
relationship includes a dependence on Prandtl Number then you could use an
average value of Prandtl Number based on an initial Shell&Tube run without
performance data.

Friction Factor
For each Reynolds Number in a Shell&Tube performance data table, you input
an associated friction factor. The definition of the friction factor is:
Pressure Gradient = 2 * f * [mass flux]^2 / ([density]*[hydraulic diameter])
Where the mass flux and hydraulic diameter are based on an empty tube or
channel (for tube side flow the hydraulic diameter is the tube inside
diameter). For shell side flow it is that for axial flow within the bundle.
 Shell&Tube: Hetran Condensation Model –
Contran
Contran is a transition utility provided for users of the Aspen Hetran program
which Aspen Shell&Tube has replaced. Contran lets you setup a new case in
the Hetran style, or import an existing Hetran case, run it and view the
results. It is intended particularly for those who have experience that Hetran
condensing coefficients apply for cases they are modeling. These condensing
coefficients sometimes differ significantly from those predicted by the
technically more advanced methods in Shell&Tube.
 Shell&Tube Convergence Options
A number of new input items give you extra control over the calculation when
the New Calculation Method is used. The default settings for all these items
should normally be adequate, but you can adjust them if you want reduced
calculation times – perhaps at the expense of reduced convergence accuracy
or stability, or if there are cases where there are convergence problems with
the default settings.
The calculation is an iteration at which the current heat load, defined by
stream enthalpy profiles along the exchanger, is updated using the calculated
heat load from heat transfer, determined by integrating the product of local
overall heat transfer coefficient and local stream to stream temperature
difference over the heat transfer surface of the exchanger.
A parallel calculation for pressure updates the current pressure at each point
in the exchanger using the calculated pressure change, based on pressure
gradients and changes at points within the exchanger.
Maximum Number of Iterations
Convergence Tolerance - Heat Load
Convergence Tolerance - Pressure
Relaxation Parameter
Calculation Grid Resolution
Convergence Criterion
Calculation Step Size
 Shell&Tube Maximum Number of Iterations
This is the maximum number. The default is 500 and the upper limit is 1000.
Most cases converge in a few tens of iterations. If a case does not converge,
but the message indicates convergence was close, it may be worth increasing
the number.

See also:
Convergence Options
 Shell&Tube Convergence Tolerance - Heat Load
Separate convergence tolerances can be set for heat load and pressure. The
tolerance is the difference between current and calculated values of heat load
or pressure, expressed as a fraction of the current value.
For Checking calculations, where the heat load or pressure change are
specified as being constant, the definitions are adapted, so that the specified
convergence tolerance is applied to the fractional change in area ratio, or in
the ratio of calculated to specified pressure change, rather than the heat load
or pressure drop.
All tolerances are dimensionless (change in value divided by value), and
default to 0.0001

See also:
Convergence Options
 Shell&Tube Convergence Tolerance - Pressure
Separate convergence tolerances can be set for heat load and pressure. The
tolerance is the difference between current and calculated values of heat load
or pressure, expressed as a fraction of the current value.
For Checking calculations, where the heat load or pressure change are
specified as being constant, the definitions are adapted, so that the specified
convergence tolerance is applied to the fractional change in area ratio, or in
the ratio of calculated to specified pressure change, rather than the heat load
or pressure drop.
All tolerances are dimensionless (change in value divided by value), and
default to 0.0001

See also:
Convergence Options
 Shell&Tube Relaxation Parameter
The basic heat transfer calculation involves updating the current heat load
profile using a value calculated from the predicted heat transfer. The
relaxation parameter R is used in the relation
Updated value = (1-R) x Current value + R x Calculated value.
For calculation stability reduced values of R are used in early iterations, or if
potentially difficult convergence situations are encountered. The value here is
used when convergence is proceeding normally. A lower input scales down the
reduced values early in the calculation as well. For cases which fail to
converge, a reduced convergence parameter (and/or higher resolution) may
help, but at the expense of more iterations being needed.
 Shell&Tube Calculation Grid Resolution
The options are:
· Low
· Medium
· High
· Very high

The resolution determines the number of calculation grid points along/across

the exchanger.
There are four levels of resolution, Low (few points), Medium (default), High
and Very High. The actual number of points depends on the type of shell,
number of shells in series, and the number of passes per shell. In a typical E-
shell, Medium gives 20 points along the shell, for the shell side, and for each
tube side pass.
Using more calculation points may increase the accuracy when there are
regions with very different heat transfer coefficients. It will increase the
calculation time, but may make the calculation more stable.
The Resolution is only available with the New Calculation Method
 Shell&Tube Convergence Criterion
The options are:
· Set default
· Stop when fully converged
· Continue to max iterations
The standard criterion for convergence is that both the pressure change and
heat load calculations must have converged to the specified accuracy, but less
restrictive conditions can be imposed if desired. It is also possible to specify
that the calculation proceeds beyond convergence, to the specified maximum
number of iterations. This can help double check that true convergence has
been achieved, rather than a slowly drifting in a close approximation to
convergence.
 Shell&Tube Calculation step size
This input provides an additional control on the (relative) size of the changes
to the current heat load from one iteration to the next. It will mainly have an
effect early in the calculation when changes are large. Setting a small value is
equivalent to an additional reduction in relaxation parameter when the
calculation is far from convergence.
 Shell&Tube: Pressure Calculation Option

The two main options available are

· Predict Outlet Pressure
· Predict Outlet Pressure, subject to a specified minimum pressure
In order to determine pressures along the exchanger, pressure changes to all
points along the exchanger (friction losses and gravitational and
accelerational changes) are first calculated. These are then used to calculate
the actual pressure at each point, assuming the inlet pressure is fixed and
working towards the calculated outlet pressure. It is possible that the
calculated pressure changes will be much larger than anticipated, possibly
even larger than the inlet pressure. For gases, large pressure changes give
reduced densities which in turn give even larger pressure changes.
In a real exchanger, this would imply choked flow, but when running the
program, it can arise from an error in the specified flow rate or an error in the
specified geometry giving too low a flow area.
The second of the above options, the default, helps prevent this run-away
situation by imposing a minimum calculated outlet pressure. If necessary,
calculated pressure changes are scaled before being used to calculate local
pressures to ensure that the outlet pressure never falls below a minimum
pressure which you can specify. With the first option, there can also be a
program-imposed scaling but only as a safety mechanism to prevent negative
pressures.
Whenever pressures derive from scaled pressure changes, a warning message
is produced.
The three other calculation options are
· Predict Inlet pressure
· Predict Inlet Pressure, subject to a specified minimum pressure
· Pressure Checking
Predicting the inlet pressure to achieve a specified outlet pressure can
sometimes be useful. The option of imposing a minimum pressure is unlikely
to be needed, but is include for completeness.
Checking a pressure means assuming that the inlet and outlet pressure are as
specified in the input and reporting the multiplier by which the calculated
pressure drop would need to be multiplied to achieve the specified inlet to
outlet pressure change.
If you do elect the option of simply calculating an outlet pressure, the
program will prevent subzero pressures being predicted, but will still permit
very low pressures to be predicted. Pressure drops increase when gas
densities are very low, so when a pressure drop problem occurs, it is easy for
it to generate a run-away situation where extremely high pressure losses are
predicted.

See also:
Checking and Simulation, Pressure
 Shell&Tube Multiplier for Number of Tube
Passes
The maximum number of passes which can be specified for Shell&Tube is 16.
By inputting a multiplier, however, you can model exchangers with more than
16 passes.
For example, to model an exchanger with 20 passes, you could specify 10
passes and a tube pass multiplier of 2. The exchanger geometry will be based
10 passes and this is what you will see in the Tube Layout. The thermal
performance, however, will be calculated for an exchanger with 20 passes.
The tube side mass flux, used to calculate tube side heat transfer coefficients
and frictional pressure gradients, will be based on 20 passes, as will the flow
length along which the tube side pressure drop is based.
You should explicitly specify the total number of tubes in the exchanger, to
make sure this is correct, since a tube layout with 20 passes will often have
slightly fewer tubes than one with 10.
The pass multiplier does not have to be an integer. For example, 20 passes
could be modeled as 16 passes and multiplier of 1.25. A multiplier of 2,
however, would mean that you could edit the tube layout, removing a line of
tubes in the middle of each of the 10 passes, to give a tube layout that
appeared to have 20 passes.
Whenever you specify a pass multiplier, you will get a Results Warning,
reminding you that the geometry is based one number of passes, while the
performance is based on a different number. There is a further warning
should the multiplier give you a non-integral number of passes.
The multiplier is not applied if the basic exchanger has a single pass. Modeling
20 passes by specifying a 2-pass exchanger with a multiplier of 10 is possible
but unwise, since temperature difference effects may not be modelled
accurately. Once the number of passes exceeds 4 or 6, there is usually little
change in multi-pass temperature difference effects.
The multiplier can be used in Design mode; a multiplier of 2 is recommended,
but check any Design carefully, to get the number of tubes correct.
 Shell&Tube Setting Plan
The Setting Plan details a scaled drawing of the exchanger and includes the
following data:
Overall length
Bundle/Tube Pulling Length
Location and orientation of Nozzles
Location and orientation of Supports
Location of Baffles

The following tables are also included:

Headings/Remarks
Design Codes and Standards
Design Data
Weight Summary
Nozzle Data

Click the left-hand mouse button to zoom in on an area of interest.

Click the right-hand mouse button to display a menu from which the following
options can be selected:
Exchanger only
End Views only
Draw Internals
Draw Border
Inlet Channel on Left
Nozzle/Shell Intersection
Dimension to Tubesheet Face
Draw Complete Exchanger
Draw Dimensions
Nozzle Designations

The Setting Plan can be:

Printed
Copied to the clipboard
Saved as in file in the following formats: dxf, bmp, svg, wmf
 Shell&Tube: Storage of Recap of Designs

In order to permit results of a sequence of calculations to be compared, the

Recap of Designs facility stores tabulated values of key output parameters and
lets you customize the table by adding values. It also lets you select and
reload a previous case in the sequence.
Full recovery means that the facility to select and reload a case is available.
Table only means that it is not. An indication of the whether or not a case
can be selected for full recovery is given in the Recap of Designs table. The
case as initially loaded (case A in the Recap table) is always fully recoverable.
Storing all input and output values at the end of every run is time consuming
and unnecessary if the Select/reload facility is not going to be used.
This input item was introduced to accelerate calculation times.

See also:
Application Control
 Shell&Tube Overall Performance
This screen gives information to help you evaluate the surface area
requirements in the clean, specified fouled/dirty (as given in the input), and
the maximum fouled/dirty conditions.
The clean condition assumes that there is no fouling in the exchanger, in the
new condition. The overall coefficient shown for this case has no fouling
resistance included. Using this clean overall coefficient, the excess surface
area is then calculated.
The specified foul condition summarizes the performance of the exchanger
with the overall coefficient based upon the specified fouling.
The maximum fouled condition is derived by taking the specified fouling
factors and increasing them (if the exchanger is oversurfaced) or decreasing
them (if undersurfaced), proportionately to each other, until there is no over
or under surface.
The distribution of overall resistance allows you to quickly evaluate the
controlling resistance(s). You should look in the "Clean" column to determine
which film coefficient is controlling, then look in the "Spec. Foul" column to
see the effect of the fouling resistances. The difference between the excess
surface in the clean condition and the specified fouled condition is the amount
of surface added for fouling.
You should evaluate the applicability of the specified fouling resistances when
they dictate a large part of the area, say more than 50%. Such fouling
resistances often increase the diameter of the heat exchanger and decrease
the velocities to the point where the level of fouling is self-fulfilling.

The Heat Transfer Resistances are graphically displayed on the Heat Transfer
Resistance Diagram at the bottom of the screen.
 Shell&Tube Resistance Distribution
The Heat Transfer Resistances are graphically displayed on the Heat Transfer
Resistance Diagram at the bottom of the screen.
 Shell&Tube: Shell by Shell Conditions
When there are multiple shells in series, the table of shell by shell conditions
lists the heat load in each shell, and the temperature, pressure, and quality
(vapor mass fraction) of both the shell side and tube side streams at inlet to
and outlet from each shell.
The table is also produced when there is only a single exchanger, but in this
case the information merely duplicates what is given elsewhere on the overall
exchanger performance.
The table also lists the mean shell metal and mean tube metal temperatures
in each shell, together with the maximum and minimum tube metal
temperatures. The mean temperatures are distance weighted averages,
appropriate for use in mechanical design calculations. The corresponding
values for the overall set of exchangers are given on the MTD & Fluxes tab
under the Heat Transfer results section.
 Shell&Tube: Hot Stream Composition
If stream composition information is provided as part of the stream properties
input, then composition information is output at the stream inlet and outlet
conditions.
The output composition information includes both mass and mole fractions
and the mass flowrates for each component. These are provided both for the
overall stream and for each of the phases making up the stream.
The output values are based on interpolation of the input composition
information to determine values at the temperatures and pressures
appropriate to inlet and outlet conditions. They thus correspond to phase
equilibrium conditions, which is a good approximation to what applies in most
exchangers. They do not allow for any phase separation effects that might
occur in special cases such as reflux condensers.
 Shell&Tube: Cold Stream Composition
If stream composition information is provided as part of the stream properties
input, then composition information is output at the stream inlet and outlet
conditions.
The output composition information includes both mass and mole fractions
and the mass flowrates for each component. These are provided both for the
overall stream and for each of the phases making up the stream.
The output values are based on interpolation of the input composition
information to determine values at the temperatures and pressures
appropriate to inlet and outlet conditions. They thus correspond to phase
equilibrium conditions, which is a good approximation to what applies in most
exchangers. They do not allow for any phase separation effects that might
occur in special cases, for example where phases exit at different
temperatures.
 Shell&Tube Heat Transfer Coefficients
This output section shows the various components of each film coefficient
Depending on the application, one or more of the following coefficients are
shown:
Desuperheating
Condensing
Vapor sensible
Liquid sensible
Boiling
Liquid cooling
The Reynolds number is included so that you can readily evaluate if the flow
is laminar (under 2000), transition (2000-10000), or turbulent (over 10000).
The fin efficiency factor is used in correcting the tube side film thermal
resistance and the tube side fouling factor resistance.
 Shell&Tube MTD & Flux
Temperature differences
Three mean temperature differences are shown. The overall effective MTD is
based on a heat load weighted average of the actual temperature differences
along all passes in all exchangers. This is based on the calculated solution. It
depends not only on the exchanger duty, but on the number of passes, and on
how that duty is distributed within the exchanger.
The one pass counterflow LMTD is based on a nominal 1-pass counterflow
exchanger performing the calculated duty. It is based on integrating the heat
load weighted inverse temperature difference, which is equivalent to the way
the conventional log-mean temperature difference is obtained in theoretical
exchangers where constant heat transfer coefficients and specific heat permit
an analytical solution. Allowance is made for the calculated pressure change
of each stream, but this change is assumed to be linearly distributed with
enthalpy change. The one-pass counterflow LMTD thus depends on the
exchanger performance, but does not depend on the detail of the exchanger
geometry, or on the heat transfer phenomena occurring within the
exchanger.
The end point LMTD is the LMTD that would be obtained in a pure counteflow
exchanger with the specified duty if the fluids were single phase with constant
specific heat and the heat transfer coefficients were constant.
The LMTD correction factor is the ratio of the overall effective MTD to the end
point LMTD. In general, multiple passes reduce the correction factor below
unity while the actual variation of temperature with enthalpy of each fluid can
either reduce or increase the correction factor so that values above unity are
sometimes possible. The distribution of heat transfer coefficient and pressure
change along the exchanger can also have an effect on this parameter.
Heat Fluxes
The overall actual heat flux across the exchanger is the total duty divided by
total area (based on tube OD).
The highest actual heat flux is the largest local heat flux at any point within
the exchanger(s).
For a liquid being heated, there is a critical heat flux at which as stable boiling
situation would break down, the heating surface would be covered in a
blanket of vapour, and the heat transfer would be much released. The critical
heat flux can change from point to point within an exchanger, depending for
example of the relative amounts of liquid and vapour present in the bulk fluid.
Since the heat flux also varies from point to point within the exchanger, the
situation is rather complicated, so two relevant parameters are given. One is
the highest ratio of actual heat flux to critical heat flux. If this ratio is below
unity it indicates that critical heat flux is unlikely to be a problem. The critical
heat flux at this highest ratio is also given since this is the most important
value of the critical heat flux.
It should be remembered that there is a degree of uncertainty in all critical
heat flux calculations, so if the ratio of actual to critical heat flux is not far
below unity, there is still a potential risk.
When critical heat flux is predicted, by default the local heat transfer
coefficient is reduced to a lower value appropriate to transfer through a gas
film. The coefficient is reduced over a transition region above the critical flux,
to represent in some measure the complicated physics associated with boiling
breakdown.
Wall temperatures
Four wall temperatures are given:
· The mean shell metal temperature is calculated by assuming that the
shell metal is at the same temperature as the shell side fluid. The mean is a
distance weighted average, appropriate for calculation of thermal expansion
and thermal stresses.
· The mean tube wall temperature is also a distance weighted average. It
relates to the mean metal temperature mid-way between the inner and outer
surfaces of the tube at each point. It is the average over all the tubeside
passes.
· The maximum and minimum tube wall temperatures are also given.
These again relate to the metal temperature midway between the tube
surfaces. This gives a good approximation to the range temperatures in
contact with the fluids. The actual temperatures that the fluids see will of
course be those at the surface of any fouling layer (which will in general be
different from the tube metal surface temperature). Graphical and tabular
information on stream, wall, and fouling surface temperatures, available in
the stream details output, can also be helpful.
The four temperatures given on this output tab all relate to the overall
exchanger system, and thus may give means and limit values over multiple
exchangers in series when these are present.
Equivalent values of the mean shell metal and mean tube metal temperatures
and the maximum and minimum tube temperature in individual shells are
given on the Shell by Shell Conditions tab.
Shell&Tube Duty Distribution
 Shell&Tube Pressure Drop
The pressure drop distribution is one of the most important parts of the
output for analysis. You should observe if significant portions or the pressure
drop are expended where there is little or no heat transfer (inlet nozzle,
entering bundle, through baffle windows, exiting bundle, outlet nozzle).
If too much pressure drop occurs in a nozzle, consider increasing the nozzle
size. If too much is consumed entering or exiting the bundle, consider using a
distributor belt. If too much pressure drop is taken through the baffle
windows, consider a larger baffle cut.
On the shell side, the program determines the dirty pressure drop by
assuming that the fouling will close the clearance between the shell I.D. and
the baffle OD and the clearance between the baffle and the tube OD. The
bypassing around the outside of the bundle (between the shell I.D. and the
outer tube limit) is still present in the dirty pressure drop.
The program determines the dirty pressure drop in the tubes by estimating a
thickness for the fouling, based on the specified tube side fouling resistance,
which decreases the cross-sectional area for flow.
The velocity distribution, between the inlet and outlet nozzle, is shown for
reference. In other parts of the output, the velocity, which is shown for the
shell side, is the diametric cross flow velocity. For the tube side it is the
velocity through the tubes. For two phase applications, the velocities for cross
flow, through baffle windows, and through tubes are the highest velocities
based on the maximum vapor flow.
 Shell&Tube Thermosiphon Piping
This output only appears for thermosiphon applications.
There are three sections, giving reference points (heights), pressure points,
and pressure changes. The results of the thermosiphon stability analysis are
also given.
In the heights section, three of the heights are repeats of inputs; the height
of the exchanger outlet is calculated.
Under pressure points, the pressure, and in some cases the corresponding
temperature and vapor mass fraction are also given. The pressure increases
from the column liquid surface to the exchanger inlet, then progressively
decreases until the exit from outlet piping is again equal to the column
pressure.
The same phenomenon is shown in the pressure changes table. .In the inlet
circuit there will be a gravitational pressure increase, and a relatively small
frictional loss, giving an overall pressure increase. This should be matched –
to a good approximation - by the pressure decreases in the exchanger and
outlet circuit. An important feature of this table is the “unaccounted” pressure
changes, in the inlet and outlet circuits. These arise from because the fixed
flow will not in general give a pressure balance around the thermosiphon
circuit. The inconsistency (unaccounted change) may be in the inlet or outlet
circuit, depending on the particular calculation. You should judge whether the
size of these inconsistencies, relative to other pressure changes, is
acceptable.
For the exchanger, nozzle changes are entirely due to frictional losses.
Gravitational changes between the inlet to the nozzle and the inlet to the
exchanger – that is to the shell or the tubes – are not included in the
exchanger pressure changes. They are actually incorporated into the inlet and
outlet line gravitational changes, since this gives a simpler definition of these
changes, without ignoring any of the circuit pressure changes.
 Shell&Tube Thermosiphon Piping Elements
This output only appears for thermosiphon applications.
This section lists the calculated pressure drop for each element within the
Inlet and Outlet Circuit Piping.
 Shell&Tube Flow Analysis
Crossflow
Only the crossflow (and part of the window flow) contribute to the heat
transfer. The cross flow fraction usually ranges from 30-70 % of the total
flow. Lower values will give lower pressure drops, but generally indicate a
poor design.

Window
This is the sum of:
Crossflow
Bypass Flow around the outside of the bundle
Bypass Flow in in-line pass partition lanes

Baffle hole to Tube OD diametric clearance

This is the location of the primary leakage stream and is sometimes referred
to as the "A" stream. Leakage through this opening can significantly decrease
the pressure drop and will also reduce the film coefficient.

Baffle OD to Shell ID diametric clearance

This is a secondary leakage stream and is sometimes called the "E" stream.

Shell ID to Bundle OTL diametric clearance

This is called a bypass stream, because it largely bypasses the heat transfer
surface. This is also known as the "C" stream. When this shell-bundle OTL
clearance is large as in the case of an inside floating head exchanger (TEMA
rear head types S & T) the program automatically adds sealing strips to force
the flow back into the bundle.
 Shell&Tube Thermosiphons and Kettles
The physical properties used in the calculation are listed on this tab.
 Shell&Tube Fluid-Elastic Instability
Fluid-elastic instability (or fluid-elastic whirling) is perhaps the most
important of the mechanisms of flow induced vibration. Damage caused by
fluid-elastic instability can be severe and result within minutes. Unlike other
Vibration Mechanisms this is not a resonant vibration and ultimately tube
movement is only limited by contact with other tubes or mechanical
constraints. For fluid-elastic instability the phenomenon occurs above a
critical velocity rather than a resonant frequency.
Essential parameters of fluid-elastic instability are:
1) The critical flow velocity determines the point of instability
2) The level of Damping for the tube
3) The Natural Frequency for the tube
4) Heat exchanger geometry
5) Fluid phase and properties
Essential notes:
a) Fluid-elastic instability must be avoided. The results from other
mechanisms (e.g. Acoustic Resonance) may be acceptable, but fluid-elastic
instability will fail.
b) Fluid-elastic instability applies to the entire tube. It cannot be assessed for
the tube's individual spans or regions (inlet, midspace, outlet).
c) Care needed during non-standard operation (e.g. start-up / shutdown)
Shell&Tube assesses fluid-elastic instability by comparing the actual mass flow
into the exchanger with the critical mass flow for onset of instability (W/WC in
the Tables of Fluid-Elastic Instability Assessment). When the ratio of actual to
critical mass flow is greater than 1.0, Shell&Tube identifies this with asterisks
(*) in the output.
The calculations for fluid-elastic instability are highly dependent on Damping,
which may vary throughout a heat exchanger. The level of damping can be
indicated by a term called the logarithmic decrement (L DEC in the Tables of
Fluid-Elastic Instability Assessment).

See also:
Vibration Analysis: Overview
 Shell&Tube Resonance Analysis
Sound (acoustic) waves can be propagated inside the cavity formed by the
shell of the heat exchanger.
The parameters which determine the acoustic resonance frequency are:
1. Shell diameter increase to decrease acoustic resonance frequency
2. Velocity of sound increase to increase acoustic resonance frequency
The velocity of sound depends on the phase of the shell side fluid and its
properties. In fluids the velocity of sound is usually so large that the acoustic
resonance mechanism is not usually a problem. It may be more relevant to
gases and mixtures of gases and liquids.
Principle features of acoustic resonance are:
1) The main consideration is whether there is a "Lock-In" Effect with the
Vortex Shedding and/or Turbulent Buffeting frequencies
2) Damage to tubes may not occur, but the NOISE may be unacceptable.
3) There can be many acoustic resonance frequencies. Shell&Tube considers
only the lowest frequency (the first mode)
4) Acoustic baffles may be inserted inside the tube baffle space to prevent
acoustic resonance
Shell&Tube uses the Liquid Compressibility (Isothermal Modulus of Rigidity) of
water in the calculation of the velocity of sound for liquid and two-phase
streams. This approximation for non-water streams is usually acceptable.
Refer to HTFS Handbook Sheet VM5 for more information.

See also:
Vibration Analysis: Overview
 Shell&Tube TEMA Fluid Elastic Instability
Flow-induced tube vibration on the shell side of a heat exchanger can cause
serious damage to a tube bundle, sometimes very quickly. It is very important
to try to avoid potential vibration damage by making changes at the design
stage to limit the probability of vibration occurring. Although vibration
analysis is not yet an exact science, TEMA has included two methods, which
were fully implemented in the Aspen Hetran program.
The calculations are done at three or four points:
Inlet
This is the longest tube span at the inlet. For segmental baffles (except NTIW)
this is from the inside face of the tubesheet to the second baffle. For grid
baffles and NTIW this is from the inside face of the tubesheet to the first
baffle.
Bundle
This is the longest tube span excluding the inlet and outlet zones. For
segmental baffles (except NTIW) this is two times the baffle spacing. For grid
baffles and NTIW this is the baffle spacing.
Outlet
This is the longest tube span excluding the inlet and outlet zones. For
segmental baffles (except NTIW) this is two times the baffle spacing. For grid
baffles and NTIW this is the baffle spacing.
Other areas
This is for other tube spans resulting from using intermediate supports with
the NTIW construction.

Note: TEMA V-5.1 states that the potential for vibration is evaluated for each
individual unsupported span, with the velocity and natural frequency
considered being that of the unsupported span under examination.
TEMA V-10 states that the reference cross-flow velocity V, at every location,
should be less than the calculated critical velocity Vc, for that location.
See also:
Vibration Analysis: Overview
 Shell&Tube TEMA Amplitude and Acoustic
Analysis
The acoustic resonance analysis is also based on the latest edition of TEMA and
is done at the same points described previously for vibration analysis.
Acoustic resonance is a problem of sound, but not usually tube vibration.
Therefore its avoidance might not be as critical as tube vibration, but it still
should be avoided if practically possible.
When a low density gas is flowing on the shell side of the heat exchanger at a
relatively high velocity, there is the possibility that it will oscillate as a column
somewhat like an organ pipe. This results in a noise which can be very loud.
Noise levels of more than 140 decibels have been reported, which would be
very painful to the human ear.
TEMA V-12.4 Acoustic Resonance
Incidence of acoustic resonance is possible if any of the following conditions is
satisfied at any operating condition:
· V-12.41 Condition A Parameter - TEMA recommends checking the
relationship between the vortex shedding frequency and the turbulent
buffeting frequency of the tubes and the acoustic frequency of the gas. If
these frequencies are close, the tubes may vibrate in resonance. The program
indicates vibration when the acoustic frequency matches either the vortex
shedding frequency or the turbulent buffeting frequency of the tubes within +
or - 20%.
· V-12.42 Condition B Parameter - Reference Crossflow Velocity >
Calculated Velocity
· V-12.43 Condition C Parameter - Reference Crossflow Velocity >
Calculated Velocity and Ratio Parameter > 2000
See also:
Vibration Analysis: Overview
 Shell&Tube: Vibration Tubes
The risk of vibration in any tube in an exchanger depends on where it is
supported, by baffles or other supports, and on local flow velocities along its
length. The program automatically selects a small representative set of tubes
to perform vibration checks on.
Additional facilities, introduced in V7.3.2.0 include:
· An extended set of program-selected representative tubes are checked
· An option to select any other tube in the exchanger for vibration
checking (up to six such tubes at a time)
· Display of vibration-check tubes on the Tube Layout, both program-
selected and user-selected tubes
· Enhanced tabular output of tube vibration and resonance results
To see vibration tubes in the Tubesheet Layout output, click the Vibration
Tubes box above the diagram. A red V appears on the vibration tubes, and a
table with further information on these tubes appears below the Layout. If
there is a very large number of tubes in the layout, you need to zoom in to be
able to see this. If there is a vibration or resonance risk, the tube is drawn as
two displaced circles to give a visual indication of the problem. For vibration,
the tubes are displaced horizontally, and for resonance, vertically. Four
displaced tubes are drawn when both effects are present. The extent of the
risk is also indicated in the table below the layout.
Each vibration tube has a number which allows you link it with the main
Vibration and Resonance Analysis results. Numbers 1-8 are used for program-
selected vibration tubes, and numbers 10-15 for user selected ones. Numbers
21-28 are used for program selected tubes in the second shellside flow half of
an F-,G- or H-shell. Not every number will appear, because numbers define
representative locations and are often specific to certain baffle orientations or
types.
The program-selected vibration tubes are chosen to be representative of
potential worst cases. You will see that they are concentrated in the baffle
windows, where support for the tubes is less frequent, and near inlet and
outlet nozzles, where flows are highest.
To select another tube for vibration checks, navigate to Geometry Summary
| Geometry and specify Use Existing under Tube Layout. On the Tube
Layout tab, right-click a tube to select it. Select Vibration on the context
menu, and then Mark.
After you run the program, you will see your additional tube(s) in the
Vibration and Resonance Analysis results and on the Tube Layout.
See also
Vibration: Tube Rows Selected
 Shell&Tube: U-Bend Schedule
For an exchanger with U-tubes, the U-bend schedule lists the required
number of U-bends of each size. It shows the length of the bend region and
the total tube length (bend plus two straights) for each size.
 Shell&Tube Interval Analysis (Analysis along
Shell)
The Interval analysis section provides you with table of values for liquid
properties, vapor properties, performance, heat transfer coefficients and heat
load over the shell & tube side temperature ranges.
 Shell&Tube Physical Properties (Analysis along
Shell)
The physical properties used in the calculation are listed on this tab.
 Shell&Tube Plots
This tab allows you to create plots from the data displayed in the interval
analysis tables.
Select an X variable and a Y variable to create the required plot.
Various controls are available for zoom-in/out, printing, copying, or saving
the plots.
 Shell&Tube Interval Analysis (Analysis along
Tubes)
The Interval analysis section provides you with table of values for liquid
properties, vapor properties, performance, heat transfer coefficients and heat
load over the shell & tube side temperature ranges.
 Shell&Tube Physical Properties (Analysis along
Tubes)
The physical properties used in the calculation are listed on this tab.
 Shell&Tube Interval Analysis (Analysis for X
and K shell)
The Interval analysis section provides you with table of values for liquid
properties, vapor properties, performance, heat transfer coefficients and heat
load over the shell & tube side temperature ranges.
 Shell&Tube TEMA Shell Types
The following shell types are defined by TEMA
E-shells are the most common shell type, in which the shell side fluid enters
at one end of the shell, and leaves at the other end.
F shells have a longitudinal baffle extending most of the way along the shell,
dividing it into two halves. The shell side fluid enters at one end of the shell,
flows in the top half along to the other end and then back in the bottom half
to an outlet nozzle at the same end as the inlet. An F shell is shorter, but of
larger diameter than the corresponding E-shell with the same heat transfer
area and stream pressure drops.
X-shells are pure crossflow exchangers. Some have a single, central inlet
nozzle at the top of the shell, and a single outlet nozzle at the bottom. Others
have a line of multiple nozzles at the top and or the bottom. Unlike other
shell types, X-shells do not need baffles to cause crossflow on the shell side.
Other shell types split the shell side flow in two, to give reduced mass flux
and reduced flow length, both of which give significant reductions in shell side
pressure loss.
J shells have a single, central inlet nozzle, and two outlet nozzles, one at
each end of the exchanger. They can also have combining flow, with two inlet
nozzles, and one outlet. HTFS uses the designation J for the single inlet
nozzle case, and uses I-shells to designate the case with two inlet nozzles.
G-shells have one inlet, and one outlet nozzle in the middle of the shell, with
a central longitudinal baffle, so that the each half of the flow goes from the
centre to the ends of the shell, then back again.
H-shells have two inlet and two outlet nozzles, located 1/4 and 3/4 of the way
along the shell. There is a longitudinal baffle, in each half of the exchanger,
so that on entry each half of the flow is split again, going either to the end of
the shell and back, or to the middle and back.
K-shells are kettle reboilers. The bundle is much smaller than the main part
of the shell, and located near the bottom of the shell. Boiling liquid flows up
through the bundle, with any unevaporated liquid falling back to the bottom
of the shell, before recirculating up through the bundle.
All shell types can have any number of tube passes.
Most shell and tube exchangers are horizontal, particularly the less common
types. Vertical shells are usually E-types.
All shell types are usually baffled to cause crossflow as the fluid flows along
the length of the shell. Exceptions are K- and X-shells, which are inherently
crossflow. Other shell types can be unbaffled; to give mainly axial flow in the
bundle, but this is unusual.

See also:
Head Types
 Shell&Tube Head Types
Front and rear end heads for a shell and tube exchanger come in a range of
types identified by a letter, designated by TEMA. The choice of front and rear
end head is primarily a mechanical design consideration. It affects whether
the bundle (and tubesheet) are fixed, or can be withdrawn from the shell for
cleaning, and whether there is simple access to the tubes for cleaning. It can
also impact on the thermal design, insofar as it affects the clearance between
the bundle and the shell.

Front End Heads

The front end is the tube side inlet end. It is also the tube side outlet end, if
there is an even number of tube side passes. Since the front end always has a
nozzle, it is also referred to as the stationary head.
A type: Channel with removable cover: Fixed tubesheet Access to tubes for
cleaning
B type: Bonnet (integral cover): Fixed tubesheet
C type: Channel integral with tubesheet, removable cover: Access to tubes for
cleaning
D type: High pressure version of C
N-type: Channel integral with shell and (fixed) tubesheet. removable cover
for access to tubes

Rear End Heads

Rear end heads do not have nozzles if there are an even number of shell side
of tube side passes. L, M and N have fixed tubesheets. Other tubesheets can
be withdrawn through the shell with the bundle.
L type: Fixed tubesheet, like A type.
M type: Fixed tubesheet, like B type.
N type: Fixed tubesheet, as N type stationary head
P type: Removable tubesheet, External packing Cover for access to tubes
S type: Removable tubesheet, Internal packing. No cover for access to tubes
T type: Removable tubesheet, Pull through floating head, no packing.
U type: U tubes: Shell closed at this end, but shape of end is not defined
W type: Externally sealed floating tubesheet. Must not be used with
hazardous fluids.
Certain Front/Rear head combinations are customarily used together.

See also:
Shell/Head Combinations
 Shell&Tube Shell/Head Combinations
For the standard TEMA shell types E, F, G, H, I ( is an inverted J), J and X, the
following combinations of front and rear heads can be regarded as normal
practice.

Front Head Rear Head

A, B, N L, M, N

A, B, C S, T, P, W

A, B, C U

For the kettle reboilers (TEMA type K) S, P and W type rear heads are not a
sensible option. U bends are frequently used, but the range of options is as
follows:

Front Head Rear Head

A, B, N L, M, N

A, B, C T, U

See also:
Double Pipe and Multi-tube Exchangers
 Shell&Tube Double Pipe and Multi-tube
Exchangers
Double-pipe and multi-tube are shell and tube type exchangers, but are not
covered by an official TEMA designation. EDR uses the terms D-shells and M-
shells respectively.
Double pipe exchangers consist of a long, small diameter, shell, with a single
tube in it. The tube usually has longitudinal fins extending to the shell, to
give extra heat transfer area. Double pipe exchangers often have a hairpin
inner tube, with a separate shell on each leg.
Multi-tube hairpin exchangers consist of a bundle of hairpin tubes, with a
separate shell on each leg of the hairpin, and a special cover over the U-bend
of the hairpin. The tubes may be longitudinally finned, but are usually plain
tubes with baffles to give crossflow. The number of tubes in the bundle is
usually much less than in a conventional shell and tube exchanger.

See also:
Shell Diameters
 Shell&Tube Pass Arrangements
Shell and tube exchangers can have a single tube side pass, but more often
have two or more passes. Multi-pass exchangers almost invariably have an
even number of passes, so that tube side inlet and outlet connections are at
the same end of the exchanger. 16 is usually the maximum number of passes
considered, because of fabrication problems.
Apart from constructional issues, the basic difference between different pass
arrangements is the magnitude of the temperature driving force for heat
transfer. Single pass co-current flow gives the lower limit and single pass
counter flow the higher limit. Multipass units come somewhere between, as do
pure crossflow units (X-shells), as do exchangers with multiple shell side
passes (F, G, H, I, J shells)
The use of a longitudinal baffle to give two shell side passes (a F-shell), in
conjunction with two tube side passes can however effectively give pure
counter flow.
Temperature driving force effects are only important where both streams
change in temperature. If one is isothermally boiling or condensing, the
temperature driving force is effectively independent of pass arrangement.
The one shell side, two tube side arrangement is referred to as a 1-2
exchanger and can be connected in series with an identical unit to give the 2-
4 exchanger (two shell passes and four tube passes). Overall the two shells
are in counter flow, and the penalty of multiple pass effects is reduced.
More importantly, the advantage of the 2-4 arrangement is that a
temperature cross is permitted e.g. where the shell-side outlet temperature is
cooled below the tube-side outlet temperature.
In any arrangement with more than one tube pass per shell-side pass the
temperature driving force is reduced below the counter flow LMTD (log mean
temperature difference). A correction factor designated by F is used to correct
the LMTD for this situation.
An F shell has two shell side passes, so with two tube side passes it is a 2:2
exchanger.

See also:
Single Pass Exchangers
 Shell&Tube Single Pass Exchangers
Single pass exchangers have good thermal efficiency and provided the
required tube length is not above the maximum permitted, are cheaper to
manufacture. There are, however two reasons why single pass exchangers
can only be occasionally specified.
Firstly, a single pass design isn't really suitable where removable bundles are
required. (The general argument still applies, however, in that a long two-
pass unit is cheaper than a short two-pass unit with the same surface).
Secondly, shell side allowable pressure drop is often a limiting factor (no-
tube-in-window baffles with intermediate supports is a possible solution to
this problem).

See also:
Allocation of Streams
 Shell&Tube Allocation of Streams
The choice of which fluid should go on the shell side and which on the tube
side is influenced by factors of safety, reliability, company practice,
maintenance requirements and capital cost
Hazardous fluids should not go on the shell side of exchangers with expansion
bellows, or with P or W type rear end heads
Heavily fouling fluids go by preference on the tube side, which is much easier
to clean
Fluids needing to be in contact with expensive materials go by preference on
the tube side.
High pressure fluids go by preference on the tube side.
Fluids with a high volume flowrate go by preference on the shell side, which
can, by reducing the number of baffles, avoid excessive pressure drop.

See also:
Nozzles - Sizing
 Shell&Tube Nozzles - TEMA Standards
For shell side nozzles there is the additional problem of high velocity fluids
impinging on the tube bundle. TEMA, which is the usual standard adopted,
lays down fairly strict requirements for this case which may be summarized as
follows:
Impingement protection, which would usually be in the form of a square plate,
6 mm (1/4 inch) thick, tack welded to the tube bundle (an 'impingement
plate'), to be provided for nozzle rho-v2 greater than;
2230 kg/ms2 (1500 lb/ft s2) for non-corrosive, non-abrasive, single phase
fluids.
740 kg/ms2 (500 lb/ft s2) for liquids which are corrosive, abrasive or at their
boiling point.
Impingement protection is always required for gases which are corrosive
and/or abrasive.
Impingement protection is always required for saturated vapors and for two
phase mixtures.
Shell or bundle entrance or exit flow area (whether impingement protection
fitted or not) is to be such that the rho-v2 does not exceed 5950 kg/ms2
(4000 lb/ft/ s2).
For tube side nozzles, TEMA standard is less restrictive, at 8928 kg/ms2
(6000 lb/ft/ s2), because there are no impingement issues.

See also
Nozzles - Achieving TEMA Standards
 Shell&Tube Nozzles - Achieving TEMA
Standards
In order to achieve these TEMA requirements, it is usually necessary to omit
several rows of tubes which would, otherwise, have occupied the shell
entrance/exit areas. Secondly, if an impingement plate is fitted, although
TEMA places no limit on the * v2 in the nozzle itself, it is common practice to
use the entrance/exit value of 5950 kg/ms2 (4000 lb/ft s2). Finally, although
TEMA is somewhat vague as to how to calculate the entrance and exit flow
areas for shell and bundle (see TEMA R 4.6) the clear intention is to limit local
velocities at the inlet and outlet regions to the specified maximum. This is
important. In a significant number (possibly the majority) of exchangers,
subject to severe damage caused by flow-induced vibration, such damage is
due to excessive velocities in the first few tube rows after the inlet nozzle,
and/or the last few tube rows before the outlet nozzle. Even where the TEMA
requirements have been strictly observed, engineers should still check these
areas carefully for possible vibration
One way of greatly reducing the fluid velocities in the inlet/outlet areas is by
enlarging the shell diameter in those areas to form so-called 'vapor belts'.
This is an expensive construction and is generally only used for services
where the shell side flow rate relative to the shell diameter is very high (e.g.
vacuum condensers).

See also:
Tube Bundles
 Shell&Tube Tube Wall Thicknesses

The most economic choice of tube thickness is the minimum required to

withstand the tube side design pressure.
Rather than calculate this for every single case, design engineers prefer to
use standard minimum values which, for the pressures and temperatures
associated with most exchanger duties, tend to be conservative. TEMA section
'C' gives recommended thicknesses which are more than adequate for most
applications. For high pressures and/or temperature it is necessary to check
whether the selected tube thickness is adequate. TEMA also gives the
maximum allowable internal pressure for tubes at various values of allowable
stress. This last property, which decreases with increasing temperature, can
be obtained from the relevant code. For high pressure on the outside of tubes
there is, unfortunately, no short-cut method for determining the minimum
tube thickness and reference must be made to recognized pressure vessel
code.
When ordering tubes it is necessary to state whether the specified wall
thickness is the average or the minimum required. This distinction is not
usually considered to be significant as far as thermal design is concerned.
When tubes are bent to form U-tubes, the thickness of the tube in the region
of the bend is reduced and it might be necessary, especially at higher
pressures and temperatures to use tubes that are thicker than normal,
particularly for the inner U-bends. TEMA R-2.31 gives further details.

See also:
Common Tube Diameters and Thicknesses
 Shell&Tube Common Tube Diameters and
Thicknesses

The most common sizes for heat exchanger tubes are 3/4 inch (19.1mm) and
1 inch (25.4mm) outside diameter, although a wide range of other sizes can
also be used.
Wall thicknesses are often quoted in BWG. Typical thicknesses used for steel
tubes are

Carbon steel 3/4 inch 16, 14, 12 BWG

Carbon steel 1 inch 14, 12 BWG

Other alloys 3/4 inch 18, 16, 14 BWG

Other alloys 1 inch 16, 14, 12 BWG

For a full list, and for other metals, see Standard Bare Tube Diameters and
Gauges
BWG correspond to the following wall thicknesses

BWG inches mm

10 0.134 3.403

12 0.109 2.768

14 0.083 2.108

16 0.065 1.651

18 0.049 1.244

20 0.035 0.889

See also:
Standard Bare Tube Diameters and Gauges
 Shell&Tube Standard Bare Tube Diameters and
Gauges

Data taken from TEMA

Carbon Steel,
O.D. Copper and
Aluminum and Other Alloys
Inches Copper Alloys
Aluminum Alloys

B.W.G. B.W.G. B.W.G.

Thickness Thickness
(Min. (Min. Thickness (Avg.
(inches) (inches)
Wall) Wall) Wall)

27 0.016 - - 27 0.016
24 0.022 - - 24 0.022
22 0.028 - - 22 0.028

1/4
22 0.028 - - 22 0.028
20 0.035 - - 20 0.035

3/8 18 0.049 - - 18 0.049

20 0.035 - - 20 0.035

1/2 18 0.049 - - 18 0.049

20 0.035 18 0.049 20 0.035

5/8 18 0.049 16 0.065 18 0.049

16 0.065 14 0.083 16 0.065

3/4 20 0.035 16 0.065 18 0.049

18 0.049 14 0.083 16 0.065
16 0.065 12 0.109 14 0.083

7/8 18 0.049 14 0.083 16 0.065

16 0.065 12 0.109 14 0.083
14 0.083 10 0.134 12 0.109
12 0.109

1
18 0.049 14 0.083 16 0.065
16 0.065 12 0.109 14 0.083
14 0.083 - - 12 0.109

11/4
 16 0.065 14 0.083 14 0.083
11/2 14 0.083 12 0.109 12 0.109

16 0.065 14 0.083 14 0.083

2 14 0.083 12 0.109 12 0.109

14 0.083 14 0.083 14 0.083

12 0.109 12 0.109 12 0.109

Notes:
Average wall tubes one BWG thicker may be used in place of the specified
minimum wall tubes
For BWG values in mm, see Common tube diameters and thicknesses

See also:
Tube Pattern and Tube Pitch
 Shell&Tube Tube Length - Maximum Value
The most common restriction on the tube length is that imposed by the
maximum available space either in the fabrication shop, in transit or on site.
As far as shop fabrication is concerned it is probable that the capacity of the
larger works far exceeds anything that the exchanger designer is likely to
require.
If both shop and site have access to deep water then transporting very long
exchangers is no problem. Where delivery must be made by road, the
allowable length will obviously be restricted, probably to around 15 to 20
meters (50 to 65 ft) depending on the country concerned. For any particular
project, the plant operator should advise design engineers of such
restrictions. This information is usually included in the project specification.
While it is relatively easy to get hold of information about maximum shipping
dimensions it is not always so easy to find out how much space is available on
site. On re-vamp projects or where replacement exchangers are being fitted,
the end user should advise the exchanger designer as to the maximum plot
area available. For new plants the plot plan is hardly ever finalized at the
time exchangers are being thermally designed and the design engineer is
often left to exercise judgment as to the maximum tube length.
Consequently, many engineers tend to use the 'standard' lengths
recommended by TEMA of 2.44, 3.05, 3.66, 4.88 and 6.10 meters (8, 10, 12,
16 and 20 ft). A maximum tube length of 6 meters is a safe value for refinery
and chemical plant where space is restricted and allowance needs to be made
for withdrawing removable bundles. On gas plants, where very large single
pass exchangers are often used, a much longer maximum length (15 meters
or more) is necessary for economic design. On offshore platforms, gas to gas
exchangers are usually installed vertically so that an economic length can be
employed.

See also:
Tube Length / Number of Passes
 Shell&Tube Tube Length / Number of Passes
For a given surface area the longer the tube length, the cheaper the
exchanger. The reasons for this are:
Lower material costs due to the reduced shell and head thicknesses required
by mechanical design codes at smaller shell diameters.
Lower labor costs associated with a reduced number of tubes (less tubesheet
drilling, etc.).
Low allowable pressure drop on the tube or the shell side can sometimes
restrict the length and in such cases it is often worthwhile going back to the
pressure drop specified and asking for an increased value since exchanger
pressure drops are often determined somewhat arbitrarily, and, also, pressure
drop unused in one exchanger can often be re-allocated to another in the
same section of the plant.
Where pressure drop on either side is not a problem very substantial savings
can be made by going for the longest exchanger possible. This is especially
true where the number of tubes can be reduced to the point where a single
tube-pass becomes viable. Not only are there then the advantages outlined
above, but also there is often a larger effective temperature difference which
consequently reduces surface area. Indeed, it can be argued that, for any
given service, the most economic exchanger is the single pass unit of such a
length to exactly use up the available tube side pressure drop.

See also:
Tube Counts
 Shell&Tube Single Segmental Baffles
Single segmental baffles are the most common baffle type. They can be
arranged to provide side to side flow (mainly used in horizontal condensers)
or up and over flow (mainly used in single phase units). The baffle cut
normally ranges from 15% to 45%.

See also
Double Segmental Baffles
 Shell&Tube Double Segmental Baffles
Double segmental baffles are normally used when there is a requirement for a
low shell side pressure drop which can not be met by a single segmental baffle
even with a large (45%) baffle cut. The lower pressure drop is achieved by
splitting the shell side flow into two paths through the exchanger. The baffle
cut is normally in the range 25% to 45%.

See also:
Triple Segmental Baffles
 Shell&Tube Triple Segmental Baffles
Triple segmental baffles are normally used when there is a requirement for a
low shell side pressure drop which can not be met by double segmental baffle.
The lower pressure drop is achieved by splitting the shell side flow into three
paths through the exchanger.

See also:
Orifice Baffles
 Shell&Tube Orifice Baffles
With the orifice baffle there is sufficient clearance between the tube and
baffle hole to allow flow past the baffle without excessive pressure drop. The
baffles do not support the tubes, or at best provide limited support to the few
tubes they touch. This arrangement should either be used with vertical tubes
or some of the baffles raised to press the tubes against the sides of the holes.

See also:
Disc and Doughnut Baffles
 Shell&Tube Disc and Doughnut Baffles
The disc and doughnut baffle is similar to the double segmental baffle in that
it is primarily used for processes with a low shell side pressure drop. However,
in practice it is not used as much as the double segmental baffle.

See also:
Rod Baffles
 Shell&Tube Rod Baffles
Rod baffles are a technique for supporting tubes with a matrix of rods instead
of the conventional perforated baffle plate. One rod baffle consists of a set of
rods welded to a ring of diameter just greater than the bundle. A ‘baffle set’
consists of four of these baffles, spaced along the exchanger axis, providing
positive 4-point support of the tubes. An exchanger will then have a number
of these baffle sets according to the tube length.

This baffle was designed principally to eliminate tube damage due to tube
vibration, since it gives primarily axial flow along the bundle, rather than
crossflow.
This RODbaffle system was developed, and is marketed (through licensees),
by the Phillips Petroleum Company.

See also:
Baffle Cut Orientation
 Shell&Tube Baffle Cut Orientation
'Orientation' here means the position of the cut edge of the baffle with respect
to the shell inlet nozzle centre line. Although any orientation is theoretically
possible only two are in general use, namely:
1. Baffle cut parallel to shell nozzle centre line (0 degree cut angle).
2. Baffle cut perpendicular to shell nozzle centre line (90 degree cut angle).
For horizontal shells with top or bottom inlet nozzles, 0 degree cut angle is
generally referred to as 'vertical cut' (or side-to-side flow) and 90 degree cut
angle as 'horizontal cut' (or up-and-over flow).. Of these two the preferred
arrangement is 90 degree cut angle since the use of 0 degree cut angle
results in a large by-pass area between the outer tube rows and the nozzles
requiring the installation of sealing strips.
For the particular case of horizontal condensers, 0 degree cut angle (i.e.
vertical cut) is often chosen since its use permits reasonable liquid-vapor
separation (which means that any non-condensables can be easily vented)
and provides a small amount of liquid subcooling. In most other cases,
including all vertically mounted exchangers, 90 degree cut angle should be
used.

See also:
Baffle Spacing and Cut
 Shell&Tube Baffle Spacing and Cut
If the calculated shell side pressure drop exceeds the maximum allowable the
design engineer will usually increase the baffle spacing and/or baffle cut until
the pressure drop is reduced to an acceptable value. As the baffle spacing is
increased, however, the resulting larger unsupported tube span renders the
tubes increasingly susceptible to damage due to sagging or flow-induced
vibration. Design engineers are, therefore, often obliged to use alternative
means for reducing shell side pressure drop such as the use of J or X-type
shells or double segmental baffles.
TEMA has laid down an absolute maximum unsupported length for various
tube sizes and materials. For exchangers with tubes in the baffle windows the
unsupported spans are the sums of adjacent baffle spacings. Note that these
TEMA values are an absolute maximum and should in no way be regarded as
a safe limit for avoiding flow induced vibration which can, and often does,
occur at spacings less than the TEMA maximum.
For baffles with no tubes in the window there is no theoretical limit on the
baffle spacing since intermediate supports can be employed to reduce the
unsupported span to any required value. If, however, baffle spacing with no
tubes in the window is increased to the point where only one baffle is
possible, then the design engineer should consider using 'rod baffle ' design
instead.
The maximum permissible baffle cut is also determined by consideration of
the maximum allowable unsupported span since, above a given cut, some of
the tubes in the centre of the bundle will not be fully supported by any of the
baffles. The exact value of the maximum possible cut depends on the
geometry of the tube bundle, but is usually taken as 45% for single
segmental and 25% for double segmental.
Baffle cuts below the maximum are usually chosen such that the free flow
area in the baffle window is roughly equal to the crossflow area at the
exchanger centre line since this avoids excessive turn-around pressure losses.
Small baffle cuts can lead to poor shell side flow distribution and minimum
values of 15% (tubes in window) and 10% (no-tubes-in-window) are
recommended.
Small baffle spacings can also result in poor shell side flow distribution. In the
days before computer aided shell side flow analysis, the minimum spacing
traditionally used was one-fifth of the shell diameter. Nowadays, given
programs like Shell&Tube, the design engineer can check whether a low baffle
spacing is going to lead in turn to an excessively low crossflow fraction and
act accordingly.
Note that an exchanger with a large number of closely spaced baffles could be
difficult to fabricate and TEMA recommends an absolute minimum spacing of
50.8 mm (2 inches), although spacings lower than this could be used in
smaller exchangers of 203 mm (8 inches) shell ID or less.

See also:
Maximum Unsupported Tube Span Length
 Shell&Tube Maximum Unsupported Tube Span
Length
Data taken from TEMA

Maximum Unsupported Span - Inches

Tube Tube Materials and Temperature Limits (deg F)

C arbon & High Alloy Steel (750) Aluminum & Aluminum Alloys
O.D. Low Alloy Steel (850) C opper & C opper Alloys at C ode
Inches Nickel-C opper (600) Maximum
Nickel-C hromium-Iron (1000) Allowable Temperature

1/4 26 22

3/8 35 30

1/2 44 38

5/8 52 45

3/4 60 52

1 74 64

11/4 88 76

11/2 100 87

2 125 110

Note: Above the metal temperature limits shown, maximum spans shall be
reduced in direct proportion to the fourth root of the ratio of elastic modulus
at temperature to elastic modulus at tabulated limit temperature. In the case
of circumferentially finned tubes, the tube O.D. shall be the diameter at the
root of the fins and the corresponding tabulated or interpolated span shall be
reduced in direct proportion to the fourth root of the ratio of the weight per
unit length of the tube, if stripped of fins to that of the actual finned tube.

See also:
Sealing Strips
 Shell&Tube Sealing Strips

If the baffle cut is in line with the nozzles, the need to provide entrance/exit
areas by leaving out tube rows will result in excessive by-passing of the tube
bundle. This problem can be avoided by fitting sealing strips. The most typical
case is a horizontal exchanger with nozzles at the top and bottom, and
vertically cut baffles. Here sealing strips consisting of thin plates fitted into
slots in the top and bottom of the baffles are normally fitted to seal the free
area between the bundle and the shell. It is usual to speak of 'pairs' of sealing
strips, each strip installed at the top of the bundle having an opposite one at
the bottom. The more strips installed, the less by-passing there will be. One
pair per three tube rows is usually sufficient.
Sealing strips are also often used to prevent by-passing between the bundle
and the shell in TEMA 'S' and (especially) 'T' types where there is a large
clearance between shell and bundle. In this case the strips would be arranged
radially around the circumference of the bundle.
See also:
Expansion Joints
 Shell&Tube Expansion Joints
Expansion joints, also referred to as bellows, are required on the shell side of
fixed tubesheet exchangers to allow movement of the shell in line with the
thermal expansion of the tube bundle. Expansion joints are also sometimes
required in single pass floating head exchangers. There are two main types of
expansion joints
Thin wall - this type of joint is more flexible than the thick wall and can
normally allow for up to 40 mm of expansion. However, they are more prone
to damage and require internal and external sleeves to protect the expansion
joint.
Thick wall - a number of pressed plate segments are welded together and
attached to the shell. This type of expansion joint is usually 4 - 13 mm thick
and can typically allow for 2 - 5 mm of expansion.
 Shell&Tube Number of Tubes (total)
Enter the Total Number of Tubes (tube count) if known.
For U-tubes the tube count is the total number of holes in the tube sheet.
See Also:
Tube Counts
Number of Tubes plugged
 Shell&Tube Tubes in Layout
This displays the number of tubes in the existing tube layout diagram.
See also:
Tube Counts
 Shell&Tube Tube Layout option
Shell&Tube determines the location of every tube in a bundle. It provides
three methods of doing this:
1 A set of internal rules, used always in Design mode, where an exchanger
geometry must be found, and used by default in Performance modes
(Simulation and Checking), where a geometry is in principle known.
2 Pass Details specification, providing a simple method of specifying the
number of rows and columns of tubes in every pass region, and hence all tube
locations.
3 Interactive graphics for adding/deleting tubes, and moving tube pass
regions, and other bundle furniture, to any desired location
These four options are selected using the Tube Layout Option input:
· New (optimum) Layout uses method 1.
· New Layout to match tube count also uses method 1, but then
artificially removes tubes.
· Specify Pass Details is for method 2.
· Use existing layout is used after applying method 3, but can also be
used simply to continue using a layout generated by any of the other
methods.
Before selecting one of these options, it is important to understand what
difference it makes to the thermal performance calculations. It is also
important to realize that there is also a separate input for Number of tubes in
the Geometry Summary input. You can omit this and the program will
determine a value from the calculated tube layout.
If you are modeling an existing exchanger, however, you will know the
number of tubes and should specify it. This number will be used to determine
the exchanger surface area and the tube side flow area, on which tube side
heat transfer and pressure drop is based. Since shell side heat transfer and
pressure drop depend only indirectly on the number of tubes, it is possible to
model the thermal performance of an exchanger, to a very good
approximation, without needing to get the tube layout determined by the
program exactly right first.
If the number of tubes calculated in the tube layout and the actual number
that you specify, are significantly different, it is probable that some input for
the bundle layout, as specified or defaulted, does not match your exchanger.
In such cases, a warning message will be produced.
See also:
Tube Layout: Overview
Tube Bundle Layout: How it is Calculated
Bundle Layout
Tube Counts
 Shell and Tube Geometry: Plugged Tubes
If an individual tube in a bundle suffers damage, it can be plugged to prevent
entry of tubeside fluid, removing the risk of cross-contamination or rupture,
while leaving the remainder of the bundle usable.
Plugged tubes can be specified in a number of ways. In all cases the tube
count is reduced by this number when determining the exchanger area and
the tubeside flow area.
On the Geometry | Tubes tab, you can specify the total number of tubes
plugged. If this is the only specification of plugged tubes, they are assumed to
be uniformly distributed (as far as possible) among passes.
If you use the Bundle | Pass Details input to specify the number of tube
rows and columns in each pass, you can also specify the number of plugged
tubes in each pass.
Plugged tubes can be explicitly located on the Tube Layout. With Use
Existing Layout, one of the editing options is to select a tube (right-click it)
and mark it as plugged. You can also unmark an existing plugged tube.
Plugged tubes appear on the layout as grayed-in circles.
When you specify plugged tubes on the Layout, you should not provide
explicit input for the total number of plugged tubes. The default for this item
will be set from your Layout input. If you do provide explicit input and it is
inconsistent with the layout specification, it will generate an error.
If you use the Pass Details option to specify the number of plugged tubes in
each pass, the program will give each an arbitrary location to remind you that
plugged tubes are present. To set the correct locations, you will need to
change to Use Existing as the Layout option, and mark/unmark as
appropriate.
 Shell&Tube Tube Length
Enter the overall length of the tubes for Fixed Tubesheet and Floating Head
exchangers.
For U-tube exchangers enter the length of the straight section of tube.
 Shell&Tube Number of Baffles
Enter the number of Transverse Baffles.
Input is strongly recommended for Checking, Simulation, and Thermosiphon
calculations.
Remember that the number of baffles is one greater than the number of
Baffle Spaces.
This item is not needed for unbaffled or rod-baffled exchangers. If you set the
number of baffles to zero, the exchanger will be assumed to be unbaffled,
even if you have not specified this under baffle type.
If you omit this item, then the program will attempt to determine a sensible
number of baffles, based on tube length, baffle spacing, and other dimensions.
A warning message will be given.
Note that the sum of the Front Head End Length and Rear Head End Length
and the Baffle Spacing times the Number of Baffles must normally equal the
Tube Length. The program will check this and make corrections if necessary.
If up-and-over flow has been specified for an E-shell with single segmental,
then there must be an even number of baffles if the shell side nozzles are on
opposite sides of the shell, or an odd number if they are on the same side. If
your input is not consistent with this, the program will adjust the number of
baffles.
For I, J and G shells, it is assumed that there is always a central baffle. The
number required is the total number of baffles in both shell side passes
including this central baffle.

See also:
Shell and Tube Geometry - Bundle Geometry
 Shell&Tube Baffle Spacing
For variable baffle pitch, enter the baffle spacing (pitch) in each region. This
is the baffle centre-to-centre distance along the exchanger in the region.
The length of each baffle region is the product of the baffle spacing and the
number of spaces in that region.
For an E-shell, if you specify a number of baffles and a baffle pitch on the
main baffles input page, these define the total length of the baffled region.
With variable baffle pitch, the sum of the lengths of all the baffle regions must
equal this total length. If they do not,
Then you will get a message saying that all your baffle spacings have been
scaled to force this agreement.
Alternatively, if you do not specify either number of baffles or baffle pitch on
the main input page, the program will use the variable baffle pitch
information to set these two parameters, and from then the various end
lengths / end spaces. After specifying the varying baffle pitch information, go
back to the main Baffles input page and check that the defaults make sense.
With split flow shells, with more than one shell side flow path, the baffle
regions you specify should cover just one such path. When a longitudinal
baffle splits the shell into two halves, each shell side flow path goes through
both haves of the shell. For F-shells the total baffled region length must be
the same in the two halves of the shell. Your baffle regions relate to one
whole shell side flow path, and thus span both halves of the exchanger. If the
baffle spacings you input do not conform to this, they will be scaled up or
down until they do. You will get a warning message to this effect.
There is a similar constraint for G and H-shells, where your baffle regions
cover all of one of the two (G) or four (H) shell side flow paths.
See also
General advice on Variable Baffle Pitches
 Shell&Tube End Length at Front Head (tube end
to closest baffle)
Enter the end length at the front head end.
This end length is defined to include the tubesheet thickness and any tube
projection (projection of the tubes beyond the face of the tubesheet). It is the
distance from the end of the tube to the center of the nearest flow baffle.
Do not confuse the end length with the 'end space', which is the length of
tube within the end length which is exposed to the shell side flow. For
example, the ‘end space’ is the distance between the back of the tubesheet
and the face of the first baffle in an ‘E’ type shell.
Note:
Front Head End Length + Rear Head End Length + Baffle Spacing x (Number
of Baffles - 1) = Tube Length. The program will check this and make
corrections if necessary.
This item is irrelevant for RODbaffled and unbaffled units.
As the Bundle Geometry varies with unit type, refer to the following sections
for detailed diagrams of each combination:
U-Tube
Fixed Tubesheet
Floating Head

Note the following special cases:

`F' Shell Type
`G' Shell Type
`H' Shell Type
`I' Shell Type
`J' Shell Type
 Shell&Tube End Length at Rear Head (tube end
to closest baffle)

Enter the end length at the rear head end, except for U-bends, for which this
item should be omitted.
The end length is defined to include the tubesheet thickness and any tube
projection (projection of the tubes beyond the face of the tubesheet). It is the
distance from the end of the tube to the center of the nearest flow baffle.
Do not confuse the end length with the 'end space', which is the length of
tube within the end length which is exposed to the shell side flow. For
example, the ‘end space’ is the distance between the back of the tubesheet
and the face of the first baffle in an ‘E’ type shell.
If there is a blanking baffle (full circle baffle support) at this end, it does not
count as a flow baffle, and does not affect the definition of this end length.
Note:
Front Head End Length + Rear Head End Length + Baffle Spacing x (Number
of Baffles - 1) = Tube Length. The program will check this and make
corrections if necessary.
This item is irrelevant for RODbaffled and unbaffled units.

As the Bundle Geometry varies with unit type, refer to the following sections
for detailed diagrams of each combination:
U-Tube
Fixed Tubesheet
Floating Head

Note the following special cases:

`F' Shell Type
`G' Shell Type
`H' Shell Type
`I' Shell Type
`J' Shell Type
 Shell&Tube Baffle Spacing at Inlet (Nozzle)
Enter the spacing between the baffles adjacent to the Inlet Nozzle(s).
For a nozzle at the end of an exchanger, it is measured from the inner
surface of the tubesheet to the center of the first flow baffle.
If there is a U-bend, it is measured from the end of the straight length of tube
to the baffle and will be zero if the flow baffle is at the point where the U-
bend begins.
If there is a full support/blanking baffle, the distance is measured to the
center of that baffle, rather than the tubesheet inner surface.
For a central nozzle, the distance is measured from the point under the
center of the nozzle to the nearest flow baffle. By default, the program
assumes a full support baffle under such a nozzle, but the same definition of
baffle spacing at inlet / outlet applies whether or not there actually is such a
full support baffle. This definition means that in J-(or I-) shells, the baffle
spacing at inlet and outlet will normally be the same, except in special
circumstances such as when there is a U-bend.
Only the baffle spacing at inlet (a TEMA sheet item) is a permitted input. The
baffle spacing at outlet is a calculated value but is displayed on the Input
screen for information.
The baffle spacing at inlet is only one method of locating the baffles. An
alternative is to supply the Front Head End Length and Rear Head End
Length.

As the Bundle Geometry varies with unit type, refer to the following sections
for detailed diagrams of each combination:
U-Tube
Fixed Tubesheet
Floating Head

Note the following special cases:

`F' Shell Type
`G' Shell Type
`H' Shell Type
`I' Shell Type
`J' Shell Type
 Shell&Tube Baffle Spacing at Outlet (Nozzle)
This value is not an input as it is calculated from the other bundle geometry
data.

See also:
Baffle Spacing at Inlet (Nozzle)
 Shell&Tube Length of Tube beyond
Support/Blanking Baffle
Support/blanking baffles are used with pull through rear end heads. A
blanking baffle means that there is a length of tube which is ineffectual for
heat transfer purposes.
The length you specify should include the tube which is under the baffle,
between the baffle and the tube plate, within the tube plate and the tube
projection beyond the plate if any.
For a U-tube bundle, where the tube length is taken to be the straight length
only, specify the distance from the baffle surface furthest from the rear head
to the end of the straight length of tube. If the blanking baffle is located
exactly where the U-bend begins, the length you enter will be the blanking
baffle thickness.
See also:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry U-Tube Bundles
Shell Side Inlet Nozzle at Rear Head with Full Diameter Support Plate at U-
Bend
Shell Side Inlet Nozzle at Front Head with Full Diameter Support Plate at U-
Bend
Shell Side Inlet Nozzle at Rear Head with nozzle over U-bends
Shell Side Inlet Nozzle at Rear Head with nozzle beyond U-bends
 Shell and Tube Geometry Fixed Tubesheet
Bundles
Shell Side Inlet Nozzle at Rear Head
Shell Side Inlet Nozzle at Front Head
 Shell and Tube Geometry Floating Head
Bundles
Shell Side Inlet Nozzle at Rear Head with Full Diameter Support Plate at
Floating Head
Shell Side Inlet Nozzle at Front Head with Full Diameter Support Plate at
Floating Head
Shell Side Inlet Nozzle at Rear Head without Full Diameter Support Plate
 Shell and Tube Geometry `F' Shell Type
Bundles
Baffled `F' Shell
Unbaffled `F' Shell
 Shell and Tube Geometry `G' Shell Type
Bundles
Baffled `G' Shell
Unbaffled `G' Shell
 Shell and Tube Geometry `H' Shell Type
Bundles
Baffled `H' Shell
Unbaffled `H' Shell
 Shell and Tube Geometry `I' Shell Type Bundle

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Distance between Baffles at central Shell Side

Cl
Inlet/Outlet Nozzle

Note: In this case, Sl = Support Plate Thickness as support is located adjacent

to U-bend.

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry `J' Shell Type Bundle

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Distance between Baffles at central Shell Side

Cl
Inlet/Outlet Nozzle

Note: In this case, Sl = Support Plate Thickness as support is located

adjacent to U-bend.

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Single Segmental
Baffles

With Single Segmental there is a single baffle form:

1) A one-piece baffle with an Outer Baffle Cut Y.

It is recommended that the outer baffle cut is input (Y).

Greater than 45% is not practical because it does not provide for enough
overlap of the baffles. Less than 15% is not practical because it results in a
high pressure drop through the baffle window with relatively little gain in heat
transfer (poor pressure drop to heat transfer conversion). Generally, where
baffling the flow is necessary, the best baffle cut is around 25%.
 Shell and Tube Geometry Double Segmental
Baffles

With Double Segmental there are two forms of baffle:

1) A two-piece baffle with an Inner Baffle Cut X (Note: This is measured from
the exchanger centerline).
2) A one-piece baffle with an Outer Baffle Cut Y.

It is recommended that the outer baffle cut is input (Y).

Note: The area cut away should be approximately equal for each baffle.
 Shell and Tube Geometry Triple Segmental
Baffles

With Triple Segmental there are two forms of baffle:

1) A three-piece baffle with Intermediate Baffle Cuts Z.
2) A two-piece baffle with two different cuts:
– An Outer Baffle Cut Y.
– An Inner Baffle Cut X (Note: This is measured from the exchanger
centerline).

It is recommended that the outer baffle cut is input (Y).

Note: The area cut away should be approximately equal for each baffle.
 Shell&Tube Tube Layout symmetry
This input item provides a facility for enforcing a particular symmetry on a
tube bundle layout, for staggered layouts in particular. There are three
options.
· Standard Symmetry
· Full Symmetry
· No Symmetry Enforced
Standard symmetry, the default, relates to the principle diameter of the
shell, which is defined by the bundle layout. For the standard layout
orientation, with horizontal bands and PP lanes, the vertical diameter is the
principal diameter. When a tube pass spans this diameter, the symmetry
ensures that there is a tubeline along the center line. When there is a central
pass partition lane, then it will be exactly central.
Full symmetry ensures that the symmetry considerations apply to both
horizontal and vertical axes of the shell.
The two symmetry cases essentially involve reducing the number of tube rows
and/or columns to enforce an odd number or even number as appropriate. A
single pass exchanger requires an odd number for symmetry; if there is a
pass region either side of the centerline, an even number is required. The
option No Symmetry Enforced does not remove any tubelines (rows or
columns) but uses the maximum number that can be fitted in.
The basic number of lines and columns is determined by the size of the shell,
making allowance for tubes removed under nozzles. In some cases, the
number of lines and columns is inherently odd or even as required, so there is
no need to make adjustments to match the symmetry requirement. In such
cases, the value selected for this input will have no effect. In such cases, No
Symmetry Enforced can give a symmetric layout, because the symmetry is
inherent, not enforced.
This input will affect the number of tubes in an exchanger, normally by a
fairly small amount. In general, removing a tubeline will reduce the number
of tubes, so No Symmetry Enforced might be expected to give more tubes
than Standard symmetry which in turn should give more tubes than Full
symmetry. This is, however, only a general rule, and it is not hard to find
counter-examples.
This input item will only shift the location of the top/bottom/left/right sides of
the bundle by a small amount, or the order of a row or column spacing. When
other considerations, such as removal of tubes under nozzles of different
sizes, impose major differences in the spaces either side of a bundle, then
there will usually still be a significant difference after imposing symmetry.
Using the New Layout calculations (V7.2 and on), this input item does not
affect the occupancy of the grid for offset layouts. Whether or not a tube is
present in the reference grid location is selected by optimizing the tubecount.
(Before V7.2, this input item could affect this occupancy.)
This input item does not affect layouts with square (90 degree) tube patterns.
This input item applies to the tube layout as generated by Shell&Tube in the
New Layout option. If you want to match a specific layout exactly, use the
Specify Pass Details option, and specify the exact number of rows and
columns you require, overall and in each pass region. If your exact layout
cannot be generated in this way, take the nearest you can get, switch to Use
Existing Layout, and use the graphical editing facility.

See also:
Tube Layout: Overview
Tube Bundle Layout: How it is Calculated
Tube Bundle Layout: How to get what you want
Bundle Layout
 Shell&Tube Tube Passes
Enter the number of tube side passes per shell.
Shell&Tube will allow up to 16 tube side passes. Both odd and even numbers
of passes are possible, but odd numbers other than one are very unusual.
For F, G and H shells, this is the total number of tube side passes per shell.
Double pipe exchangers and hairpin multi-tube exchangers (D and M shells)
have one pass per shell. Either omit the number of tube side passes, or enter
one.
See also
Tube Layout: Overview
 Shell&Tube Pass Layout
Quadrant (double banded)
Mixed (H banded)
Ribbon (single banded)
There are several possible ways to layout tubes for four or more passes. The
primary effect on the thermal design is due to the different number of tubes
that are possible for each type.
Quadrant layout has the advantage of usually (but not always) giving the
highest tube count. It is the required layout for all U-tube designs of four or
more passes. The tube side nozzles must be offset from the centerline when
using quadrant layout. The program automatically avoids quadrant layout for
shells with longitudinal baffles and 6, 10, or 14 pass, to avoid having the
longitudinal baffle bisect a pass.
Mixed layout has the advantage of keeping the tube side nozzles on the
centerline. It often gives a tube count close to quadrant and sometimes
exceeds it. The program automatically avoids mixed layout for shells with
longitudinal baffles and 4, 8, 12, or 16 passes.
Ribbon layout nearly always gives a layout with fewer tubes than quadrant or
mixed layout. It is the layout the program always uses for an odd number of
tube passes. It is also the layout preferred by the program for X-type shells.
The primary advantage of ribbon layout is the more gradual change in
operating temperature of adjacent tubes from top to bottom of the tubesheet.
This can be important when there is a large change in temperature on the
tube side, which might cause significant thermal stresses in mixed and
quadrant layouts.
See also
Tube Layout: Overview
 Shell&Tube Pass Layout Orientation
Program
Standard (horizontal)
Vertical

Tube bundle layouts comprise a number of bands, each of which may contain
one tube pass (single banded), two passes (double banded) or a mixture (as
in H-banded). This input item lets you specify whether the bands are
horizontal or vertical. If there are multiple pass partition lanes, this item is
the orientation of the majority of lanes.
When the bundle band orientation is 'Standard (horizontal)' the tube lines in
the tube layout are tube rows, while if it is vertical, lines are columns. Even
though this item is normally needed only when there are multiple passes, it
can be used with exchangers with only one or two passes, to define whether
the layout is determined in terms of rows or columns. This provides an
additional facility for determining layouts in such cases.
The default is the Standard (horizontal) layout in most cases, since for H-
banded and single banded layouts, and with tube side nozzles at the top and
bottom of the bundle, this simplifies the location of nozzles and of pass
partition plates. If any tube side nozzle is on the side of the exchanger, you
may want to reset the pass layout orientation.
Another consideration, particularly with vertical cut baffles, may be the
relative number of in-line and transverse pass partition lanes.
The vertical layout option is related to the standard option by interchanging
the X-axis (horizontal) and Y-axis (vertical) through the centre of the shell.
Note that this is different from a simple rotation of the axes.

See also
Tube Layout: Overview
Bundle Layout
 Shell&Tube Tube Pitch
Enter a value or select a standard tube pitch from the drop down list.
The default value is based on the selected Tube Outside Diameter.
See also
Tube Layout: Overview
 Shell&Tube Tube Pattern
The tube pattern is the layout of the tubes in relation to the direction of the
shell side crossflow, which is normal to the baffle cut edge.
See also
Tube Layout: Overview
 Shell&Tube Horizontal Pass Partition Width
Enter the width of the horizontal pass partition lane, tube outer surface to
tube outer surface.
In a vertical exchanger, this would be the lane which is transverse to the inlet
nozzle. In a simple banded layout, with up and overflow, all the pass partition
lanes would be described as horizontal.
The default will be 19.05mm (0.75in) if the tube pitch minus the diameter is
less than 6.3mm (0.25in), the default will be 15.875mm (0.625in).
 Shell&Tube Vertical Pass Partition Width
Enter the width of the vertical pass partition lane, tube outer surface to tube
outer surface.
In a vertical exchanger, this should be the lane which is in line with the inlet
nozzle.
In a simple banded layout, with up and over flow, there would be no vertical
pass partition lanes.
The default will be 19.05mm (0.75in) if the tube pitch minus the diameter is
less than 6.3mm (0.25in), the default will be 15.875mm (0.625in).
 Shell&Tube Orientation of U-bends
· Horizontal
· Vertical
You can specify whether the plain of U-bends is horizontal or vertical. This
item can sometimes be deduced by Shell&Tube from the Pass Layout
Orientation, but it is good practice to specify it explicitly.
See also
Tube Layout: Overview
 Shell&Tube Minimum U-Bend Diameter
For U-tube units, where the Tube Layout option is not set to Use Existing
Layout, the minimum U-bend diameter can be specified. This dimension is
measured from tube center-line to tube center-line of the inner most U-tube.
By default the Minimum U-Bend Diameter will be 3 times the Tube Outside
Diameter.
 Shell&Tube Cleaning Lane or Tube Alignment
· Fully aligned
· Unaligned
· Partly aligned
The tube alignment between passes identifies whether tube rows and columns
should line up in adjacent passes. It can be used with any tube layout, but is
particularly useful for 45 or 90 degree layouts, when it can be set when
cleaning lanes are required.
For staggered layouts, the lining up of rows and columns in adjacent passes
imposes a restriction on the possible values of pass partition lane widths, and
values will be set accordingly. For 90 degree layouts, the restriction only
applies to the central lane of an H-banded layout.
 Shell&Tube Remove Tubes below Nozzle
Select whether tubes should be removed below the nozzle.
Tubes are removed down to some chord transverse to the nozzle axis.
Equate Areas refers to the normal design procedure of basing the shell to
chord distance (within which tubes are removed) on equating flow area into
the bundle - primarily through the nozzle cylinder projection - with the nozzle
flow area.
In Projection means that there is no gap between the chord and the nozzle-
shell intersection. In Projection is an unusual option normally used only for
large nozzles.

It is normally only necessary to specify the bundle layout as Normal

(meaning tubes are removed on an equate areas basis for every nozzle) or
Full (meaning no tubes are removed under any nozzle). The option Remove
Tubes below Nozzle, for individual nozzles, is normally used only when
different options are required on inlet and outlet nozzles.
Remember that in Rating and Simulation modes, there is also an option to
explicitly specify the open distance between the shell and the bundle on each
of the four sides of the bundle. This option will override the Remove Tubes
below Nozzle option.
 Shell&Tube Tube Layout Design
Select whether the bundle is:
· Normal – tubes under the nozzle are removed
· Full – tubes under the nozzle are not removed
For D-type shells (double pipes) and unbaffled M-type shells (multi-tube
hairpin units) you should always enter Full.
There is also an input for each shell side nozzle Remove Tubes below Nozzle.
When this is specified, it over-rides the basic setting of Normal or Full bundle.
See also
Tube Layout: Overview
 Shell&Tube Shell ID to Outer Tube Limit
Diametric Clearance
Enter the diametral clearance between the tube bundle (outer limit diameter)
and the shell wall. This item is important in determining the fraction of the
shell side flow which bypasses around the bundle.
The tube bundle outer limit diameter is the diameter of the smallest circle
that can fully enclose all the tubes in the bundle. The Bundle to Shell
Diametral Clearance is the difference between this diameter and the shell
internal diameter. In a kettle reboiler, shell internal diameter adjacent to the
front head, not the outer shell id, is used.
To obtain a zero clearance, enter 0. This would imply that the outer tubes are
effectively touching the shell.
The default clearance depends on the rear head type, and is calculated by
Shell&Tube.
This item is irrelevant for D-type (double pipe) exchangers.
See also
Tube Layout: Overview
 Shell&Tube Outer Tube Limit Diameter
The outer tube limit (OTL) is the diameter of the circle beyond which no
portion of a tube will be placed. This input only applies to rating mode.
This value will be calculated as part of the Tube Layout calculation based the
type of unit being designed.
Rear Head Type L, M, N, U
Diametral clearance = 13mm
Rear Head Type S, P, W
The required diametral clearance is ultimately determined by the mechanical
design of the floating head assembly. The required clearance increases with
diameter, so at the thermal design stage an estimate is made based on the
table below.

Shell Inside
Diametral Clearance
Diameter

mm mm

<= 584.2 41

584.2 to 711.2 42

711.2 to 1016 51

1016 to 1257.3 53

> 1257.3 54

Rear Head Type T

The required diametral clearance is equal to the S type value + 80mm.
See also
Tube Layout: Overview
 Shell&TubeMech: Radiographing (RT-2 or RT-3)
Available when Spot Radiography is selected, select between RT-2 or RT-3.
The program will follow the code rules in applying the appropriate joint
efficiency as detailed in the table below.

Butt welds, Type 1

Full Spot None

Joint
RT 1 RT 2 RT 3 None
Efficiencies

Circum- Long- Circum- Longi- Circum- Long- Circum- Long-

ferential itudinal ferential tudinal ferential itudinal ferential itudinal
stress stress stress stress stress stress stress stress

(Cat. A or (Cat. B or (Cat. A or (Cat. B (Cat. A or (Cat. B (Cat. A or (Cat. B

Category
D) C) D) or C) D) or C) D) or C)

Plate C ylinders 1 1 1 0.85 0.85 0.85 0.7 0.7

Seamless
1 1 1 0.85 0.85 0.85 0.85 0.7
cylinders (pipe)

Seamless heads 1 1 0.85 0.85

Hemispherical
1 1 0.85 0.7
heads

Plate Heads 1 1 0.85 0.7

 Shell&TubeMech: Film Heat Transfer Coefficient
Thermal data retrieved from Shell&Tube results. This is done automatically
when transferring data from Shell&Tube to Shell&TubeMech. This data is used
in calculating temperature profiles across the exchanger which rovides for a
better stress analysis of components.
 Shell&TubeMech: Inlet Temperature
Thermal data retrieved from Shell&Tube results. This data is retrieved
automatically when transferring results from Shell&Tube to Shell&TubeMech.
It is used to process operating load cases.
 Shell&TubeMech: Outlet Temperature
Thermal data retrieved from Shell&Tube results. This data is retrieved
automatically when transferring results from Shell&Tube to Shell&TubeMech.
It is used to process operating load cases.
 Shell&TubeMech: Inlet Pressure
Thermal data retrieved from Shell&Tube results. This data is retrieved
automatically when transferring results from Shell&Tube to Shell&TubeMech.
It is used to verify the thickness of pass partition plates, if any, and in the
performance evaluation of the operating load cases.
 Shell&TubeMech: Outlet Pressure
Thermal data retrieved from Shell&Tube results. This data is retrieved
automatically when transferring results from Shell&Tube to Shell&TubeMech.
It is used to verify the thickness of pass partition plates, if any, and in the
performance evaluation of the operating load cases.
 Shell&TubeMech: Mean Metal Temperature
The program uses this temperature to design a fixed tubesheet and expansion
joint. If not specified, the program will use the design temperatures.
The mean metal temperatures are very important in the correct calculation of
the relative expansion/contraction of tubes and shell. It is especially
important when the program defaults to the design temperatures because
these may not be realistic. If the Shell&TubeMech input file is generated by
Aspen Shell&Tube, the mean metal temperatures are provided automatically.
 Shell&TubeMech: Highest Tube Wall
Temperature
The program uses this temperature to verify the adequacy of the tube
material and to verify that the design temperature specified is appropriate.
 Shell&TubeMech: Lowest Tube Wall
Temperature
The program uses this temperature to verify the adequacy of the tube
material and to verify that low temperature rules are appropriate.
 Shell&TubeMech: Ambient Temperature
The program uses this temperature in the calculation of the hydrostatic test
condition and in processing operating load cases. Program defaults to 70 °F or
20 °C.
 Shell&TubeMech: ASME for Thermal Cases - use
Operating Loads
Provides the option to use the operating loads in the calculation of the
exchanger. The current default is No pending changes to the ASME code.
Using the operating loads provides for a better design since it takes into
consideration how the exchanger is actually used.
Default: No
This option is only applicable to exchangers subject to thermal stresses. The
actual operating loads can be entered in the Input | Problem Definition |
Design Specifications | Heat Transfer Data and Operating Loads tab.
The program defaults to varying percentages of the design pressure and
design temperatures for the operating conditions. These defaults are more
reasonable if you have thermal data available (typically transferred from the
thermal program). However, these defaults should not be considered a
reflection of the way the unit is actually operated. For best results, enter the
actual operating conditions (up to 10) that you want the program to consider
during the design. The controlling condition will determine the final design
selected by the program. Typical operating conditions might be steady-state,
startup, shutdown, upset, cleanout, steam out, winter, summer, etc. To use
the operating conditions in the design, select Yes and make sure that the
operating conditions used by the program are reasonable. If the operating
conditions are too severe (e.g. large temperature differences between the
sides), the only reasonable solution might be to add an expansion joint in
case of fixed tubesheet exchangers.
 Shell&TubeMech: Operating Loads Table
This input table provides for combinations of operating loads that can be used
in designing the exchanger. Using these operating loads greatly improves the
accuracy of the design and insures the adequacy of the exchanger for the
intended service.
 Shell&TubeMech: 1st column: Loads
The User has 4 entries for operating loads. Four default conditions are
suggested that can be changed by the User:
• Ambient
• No flow in shell
• No flow in Tubes
• Steady state
These conditions can simulate start up, shutdown, upset conditions and typical
operation.
 Shell&TubeMech: Shell Side and Tube Side
Operating Pressures and Temperatures
The values under the operating pressures and temperatures columns and
obtained from the Aspen Shell&Tube thermal data. The User can substitute
these values for others deemed more appropriate to reflect the actual
exchanger operating conditions.
 Shell&TubeMech: Gasket Inner or Outer Metal
Ring Width
Gaskets number 1389, 1390 and 1391 have inner and outer rings.
Gaskets number 1665, 1666 and 1667 have inner rings only.
Gaskets number 1383, 1384 and 1388 have outer rings only.

You must select one of these gaskets for the program to use inner and/or
outer metal rings.

The default inner rings widths are:

Diameter Width

<=10” ¼”

> 10” 3/8”

> 50” ½”

The default outer rings widths are:

Diameter Width

<=10” 3/8”

> 10” 7/16”

> 24” ½”

> 50” 5/8”

> 70” 3/4”

These defaults can be changed in the applicable input cells.

 Shell&TubeMech: Gaskets Minimum Contact
Width
This option allows the User to apply minimum gasket widths per ASME table
2-4.
Default is No.
 Shell&TubeMech: Apply Rigidity Rules to
Floating Head Flanges designed per Appendix
1-6(d)
Default is Yes.
 Shell&TubeMech: KI Rigidity Factor
If you want to override the program’s default, specify the KI rigidity factor.
Default is 0.3.
 Shell&TubeMech: KL Rigidity Factor
If you want to override the program’s default, specify the KL rigidity factor.
Default is 0.2.
 Shell&TubeMech: Flange External Moment
Specify if the body flanges will be subjected to external moments.
If so, an equivalent pressure will be calculated to be added to the flange
design pressure.
 Shell&TubeMech: Radial Load on Flange
Specify if the body flanges will be subjected to radial loads (forces).
If so, an equivalent pressure will be calculated to be added to the flange
design pressure.
 Shell&TubeMech: Bolt Correction Factor
Specify whether you would like the TEMA or ASME bolt correction factor.
Default is TEMA.
The program multiplies the flange moment Mo by the bolt spacing correction
factor if the maximum bolt spacing is exceeded for each method (TEMA or
ASME).
The TEMA bolt correction factor is shown in TEMA RCB-11.22:

Where:
a = Bolt Diameter
B = Bolt Spacing
t = Flange Thickness
m = Applicable Gasket Factor.

The ASME method uses the same maximum bolt spacing as TEMA.

The ASME bolt spacing correction factor BSC is applied when the bolt spacing
exceeds 2*bolt diameter + flange thickness.
 Shell&TubeMech: Tubesheet Tube Hole
Tolerance Standard
Program
Standard Fit
Special Close Fit

Select the required Tube Hole Tolerance, in accordance with TEMA RCB-7.21.
The program calculates the required Tubesheet Tube Hole Nominal Diameter
based on the Tolerance selected and the Tube Outside Diameter entered.
The default is Standard Fit.
 Shell&TubeMech: Tubesheet Tube Hole Nominal
Diameter
If known, enter the tube hole diameter in the tubesheet.
See also:
Tubesheet Tube Hole Tolerance Standard
 Shell&TubeMech: Use Differential Design
Pressure
Default is No.
If Yes is selected, the program designs the tubesheets, tubes, and floating
head, if applicable, using differential pressure. It is important to insure that
the differential pressure will never be exceeded during the operation of the
equipment. See ASME UG-19(a)(1). For tubesheets, see UHX and TEMA, if
applicable. For tubes and floating heads, the program uses the differential
pressure calculated (or entered) on the tube side or shell side (the side with
the higher absolute pressure) and zero on the other side (or vacuum pressure
if specified).
 Shell&TubeMech: Actual Differential Pressure
If you have specified to design the tubesheets using a differential design
criteria, the program, by default, uses the design pressures to determine the
differential design pressure. You can override the default and specify the
differential pressure to be used.
 Shell&TubeMech: Load Transferred from Flange
to Tubesheet
The program will automatically transfer the calculated load from the body
flange to the tubesheet for the flange extension calculations. For special
design considerations, you can specify the load to be used in these
calculations.
Default: The calculated load from the body flange design per the applicable
code.
 Shell&TubeMech: ASME for Thermal Cases - use
design temperature
By default the program uses the mean metal (operating) temperatures for the
tubesheet thermal cases. Select this option to have the program use the
design temperatures for these cases instead.
 Shell&TubeMech: Tube Stresses at the Interior
of the Bundle
Default: Yes
The ASME UXH method includes the calculation of the tube stresses across
the tubesheet diameter. The older UHX method only calculated the tube
stresses at the bundle periphery.
 Shell&TubeMech: Use Flange Operating Bolt
Loads in Pressure-only Cases
Default: No
Program will use Wm1 for pressure-only cases and W for thermal cases.
 Shell&TubeMech: Calculate the Tubesheet
Flanged Extension
Default: Yes when the tubesheet has a bolt load.
Default: No when the tubesheet is ‘sandwiched’.
Specify to override the program default.
 Shell&TubeMech: Apply the Elastic-Plastic
option
Default: Yes when applicable
The program always uses the elastic-plastic option when permitted by ASME
UHX. This procedure reflects an anticipated load shift resulting from plastic
action at the tubesheet-cylinder weld joint. The net result is a load balancing
with the adjacent welded components within the maximum allowable stresses
at the specified or designed geometry. This procedure generally results in
thinner components being allowed.
 Shell&TubeMech: Design Tubesheets as Simply
Supported
Default: No
This procedure decouples integral (welded) cylinders from the tubesheet
design calculation. The objective is to isolate the welded cylinders joints from
the adjacent tubesheets; this means these joints can be treated as isolated
localized discontinuities with higher allowable stresses (see ASME UG-23(e)).
However, in most cases, any rigidity advantage provided by the welded
cylinders to the tubesheet is lost, thereby increasing the tubesheet thickness.
This procedure is used when it is difficult to increase the cylinder thickness to
meet the allowable stress when not using the simply supported procedure.
This procedure has now been expanded to all heat exchanger constructions
where a cylinder may be welded to a tubesheet (U-tube, fixed tubesheet and
floating head designs).
 Shell&TubeMech: ASME code case 2499 (DL)
Default: No
This code case involves the selection of the tube layout equivalent diameter
instead of the outer-tube-limit for the calculation of the tubesheet shear
stress. See ASME UHX-11.
Note that starting with the 2009 addenda (A09) the procedure is automatic
under certain conditions. In general, when the tubesheet shear stress controls
(as opposed to the tubesheet bending stress), it is advantageous to apply this
procedure.
 Shell&TubeMech: ASME Tubesheet Shear Load
Across Diameter
Default: Yes
This option calculates the tubesheet shear stress across its diameter. The
highest stress is typically at the periphery. For most design cases, this stress
does not control (bending controls).
 Shell&TubeMech: Display Corroded and New
Results for UHX-13
To save output space, the program displays the controlling case (corroded or
new) in the detail calculation results. However, if you see warnings that do
not correspond to the case displayed, select Yes and both corroded and
uncorroded output will be displayed. This will double the amount of output in
the tubesheet design section.
 Shell&TubeMech: Calculate Maximum Positive
and Negative Axial Expansion
Program
Yes
No

By default this option should be set to No.

When set to Yes, the program will iterate using the geometry specified and
varying the thermal data (shell and tube metal temperatures) in order to
determine how much positive and negative axial displacement can be
accommodated before a component becomes overstressed, without the use of
an expansion joint. As this option is checking an existing geometry, the
thickness of both tubesheets must be specified.
This is useful if no thermal data has been supplied and you wish to determine
how much axial expansion can be accommodated with the current geometry.
For the final exchanger design, when actual thermal data (shell and tube
metal temperatures) have been entered, this option should be switched back
to No.
 Shell&TubeMech: Calculate the Tubesheet
Thickness also using UG-34(c)(3)
Default: Yes
The program calculates the unperforated tubesheet equivalent area (the area
with no tubes) and calculates a thickness based on ASME UG-34(c)(3) – (flat
covers). If this thickness is larger than UHX, the program will use it and
provide a message to the User. For most cases, this thickness is lower than
UHX.
 Shell&TubeMech: UHX Pressure case number
(1-4) for detail output
The program defaults to the controlling pressure case (1-4) for display in the
detail calculation output. There is a minimum of 2 pressure cases (shell side
and tube side design pressures). When a vacuum is present on both sides,
then there will be 4 pressure cases. You can select any pressure case to view
in the detail calculation output.
 Shell&TubeMech: UHX Load case number for
detail output
The program defaults to the controlling load case (1-13) for display in the
detail calculation output. The first 3 are pressure-only cases and the last 10
are pressure-thermal cases. Only 4 pressure-thermal cases (load cases 4-7)
are now considered in UHX. You can select any load case to view in the detail
calculation output.
 Shell&TubeMech: Tube Expansion Maximum
Length
You can set a maximum tube expansion length limit. By default,
Shell&TubeMech uses a tube expansion length as recommended by TEMA or
as limited by the tubesheet thickness.
 Shell&TubeMech: Tube Expansion Clearance
from Shell Face
Expansion length clearance (no expansion distance) from the back tubesheet
shell side face. Default: 3 mm (1/8”).
 Shell&TubeMech: Tube Expansion Clearance
from Channel Face
Expansion length clearance (no expansion distance) from the back tubesheet
channel side face. Default: none.
 Shell&TubeMech: Tube Expansion Depth Ratio
You can specify the ratio of the tube expansion length to the total thickness of
the tubesheet. This value is used in the tube pull out load analysis.
 Shell&TubeMech: Tube to Tube Hole Friction
Factor
The friction coefficient is used in the tube-to-tubesheet expanded joints
interfacial pressure calculation per ASME appendix A. Default: 0.5
 Shell&TubeMech: Use Factor fT for Expanded
and Welded Joints
Specify if you would like factor fT (see ASME appendix A) to be used in tube-
to-tubesheet expanded and welded joints in the calculation of the tube-to-
tubesheet joints maximum axial loads. Default: No.
 Shell&TubeMech: Tubesheet Allowable Stress
at Design Temperature
If you wish to specify a special allowable design stress for the tubesheet
calculations, enter that value. If not specified, the program will use an
allowable design stress per the applicable code.
Default: Allowable design stress per the applicable design code.
 Shell&TubeMech: Yield Stress at Design
Temperature
If not provided, the program determines the Yield Stress for the material
specified at the design temperature. You may override this value by entering
it here.
Default: Yield Stress at Design Temperature based upon material specified
 Shell&TubeMech: Modulus of Elasticity at
Design Temperature
If not provided, the program determines the Modulus of Elasticity for the
material specified at the design temperature. You may override this value by
entering it here.
Default: Modulus of Elasticity at Design Temperature based upon material
specified
 Shell&TubeMech: Thermal Expansion
Coefficient
If not provided, the program determines the Thermal Expansion Coefficient
for the material specified at the design temperature. You may override this
value by entering it here.
Default: Thermal Expansion Coefficient at Design Temperature based upon
material specified
 Shell&TubeMech: Poisson Ratio
If not provided, the program determines the Poisson Ratio for the material
specified. You may override this value by entering it here.
Default: 0.3
 Shell&TubeMech: Tubesheet Material Thermal
Conductivity
If not provided, the program determines the Thermal Conductivity for the
material specified at the design temperature. You may override this value by
entering it here.
Default: Thermal Expansion Coefficient at Design Temperature based upon
material specified
 Shell&TubeMech: Baffle Tube Hole Diameter
If known, enter the tube hole diameter in the baffles.
The default is in accordance with TEMA RCB-4.2.
 Baffle Cuts
Single Segmental
In all Aspen EDR programs, the single segmental baffle cut is always defined
as the segment opening height expressed as a percentage of the shell inside
diameter.

Typical baffle cut: 15% to 45%

Double Segmental
In all Aspen EDR programs, the double segmental cut is always defined as the
segment height of the innermost baffle window expressed as a percentage of
the shell inside diameter. In the output, the baffle cut will be printed with the
percent of the inner window / percent of one of the outer windows. The area
cut away is approximately equal for each baffle.

Typical baffle cut: 20% to 42%

Triple Segmental
In all Aspen EDR programs, the triple segmental cut is always defined as the
segment height of the innermost baffle window expressed as a percentage of
the shell tube inside diameter. In the output, the baffle cut will be printed
with the percent of the innermost window / percent of one intermediate
window / percent of one outermost window. The area cut away is
approximately equal for each baffle.

Typical baffle cut: 22% to 32%

AirCooled: Quick Guide to Geometry Selection
AirCooled: Optimization of Design
 AirCooled: API Specification Sheet Descriptions
Use this sheet to specify the following optional information:
Headings, which appear at the top of the API specification sheet, Input
Summary Results, and the Title block of the drawings. Headings are 1 to 5
lines of up to 75 characters per line. Note that only the first 40 characters of
each line appear on the drawings.
Remarks, which appear at the bottom of the specification sheet output.
 AirCooled: Application Options Screen

The Application Options screen includes the following inputs:

Program calculation mode
Select geometry based on this dimensional standard
Tube side application
Outside tube application
Simulation calculation
Equipment Type
Multiple Services in Bay
 AirCooled: Tube Side Stream
The Tube Side Stream includes the following inputs:
Fluid name
Mass flow rate (total)
Temperature
Vapor mass fraction
Operating pressure (absolute)
Heat exchanged
Estimated pressure drop
Allowable pressure drop
Fouling resistance
 AirCooled: Outside Stream
The Outside Stream screen includes the following inputs:
Air/Gas mass flow rate
Required face velocity
Required bundle pressure drop
Air/Gas dry bulb design temperature
Minimum ambient temperature
Operating pressure specification
Altitude above sea level
Inlet pressure (gauge)
Inlet pressure (absolute)
Allowable pressure drop
Fouling resistance
Inlet humidity parameter
Humidity ratio
Relative humidity (%)
Flow Fraction of Air
 AirCooled: Tube Side Fouling
The Tube Side Fouling screen includes the following inputs:
Fouling option
Fouling thermal conductivity
Fouling thickness
Include fouling effect in heat transfer and pressure drop calculation
Fouling fluid curve group
Fouling curve
Fouling resistance by phase
Fouling resistance
Velocity
Temperature
Quality
Length
 AirCooled: Outside Fouling
The Outside Fouling screen includes the following inputs:
Fouling option
Fouling thickness 1
Last row for fouling thickness 1
Fouling thickness 2
First row for fouling thickness 2
Fouling thermal conductivity
 AirCooled: Geometry
The Geometry screen includes the following inputs:
Unit
Bays per unit
Bundles per bay
Fans per bay
Fan diameter
Exchange frame type
Tube side to outside flow orientation
Fan configuration
Tubes
Tube OD/ID
Tube wall thickness
Tube length
Fin type
Fin tip diameter
Fin frequency
Mean fin thickness
Tube Layout
Number of tubes per bundle
Tube rows deep
Tube passes
Tube rows per pass
Maximum number tubes per row per pass
Tube layout type
Bundle type
Transverse pitch
Longitudinal pitch
Tube layout angle
Number of circuits
 AirCooled: Tube Layout
The Tube Layout screen includes the following inputs:
You can use the Pass Layout Window to:
1) Specify, modify and view data for bundles with non-symmetrical pass
arrangements, with, or without, repeat sections
2) View bundles with symmetrical pass arrangements, with, or without, repeat
sections
If you have specified a bundle with a repeated section then the basic pattern
will be displayed in full and the remainder of the bundle will be shown with
dotted lines.
The row number, tube number and pass number of a specific tube can be
obtained by moving the mouse pointer to that tube.
Pass colors start repeating after pass 14, i.e. pass 15 has the same color as
pass 1.
Tube Counts
The total tube count and tube count per pass are shown at the right hand side
of the Window. The values are updated as tubes are added to or removed
from a pass.
 AirCooled: Unit Geometry
The Unit Geometry screen includes the following inputs:
Bays per unit
Bundles per bay
Fans per bay
Number of sides fan draws air from
Tube side to outside flow orientation
Exchanger frame type
Angle of outside flow
Tube side direction
Fan configuration
Fan inlet type
Plenum depth
Ground clearance
Chimney height above bundle
Bay Width
 AirCooled: Accessories
The Accessories screen includes the following inputs:
Louver type
Louver opening angle
Louver pressure loss coefficient
Louver control
Steam coil
 AirCooled: Clearances
The Clearances screen includes the following inputs:
Width of sideframe including fin clearance
Top of sideframe to edge of last tube row fin
Bottom of sideframe to edge of 1st tube row fin
Distance between bundles within bays
Distance between bundles in adjacent bays
Angle of sideframe to horizontal
Bundle drainage angle
 AirCooled: General
The General screen includes the following inputs:
Number of tube types
Tube shape
Tube
Tube OD
Tube ID
Tube wall thickness
Fin type
Fin material
Fin frequency
Fin tip diameter
Mean fin thickness
Fin root diameter
Fin root thickness
Major axis OD
Minor axis OD
Major axis fin OD
Minor axis fin OD
Heat transfer area scaler
Last row of tubes
 AirCooled: Serrations/Studs
The Serrations/Studs screen includes the following inputs:
Fin type
Serration width
Serration length
Serration fin method
Number of studs per crown
Stud width
 AirCooled: Bundle
The Bundle screen includes the following inputs:
Number of tubes per bundle
Tube rows deep
Tube passes
Tube layout type
Tube rows per pass
Maximum number tubes per row per pass
Bundle type
Transverse pitch
Longitudinal pitch
Tube layout angle
Tube length
Effective tube length
Number of tube supports per bundle
Tube support width
 AirCooled: Headers
The Headers screen includes the following inputs:
Header type
U-bend configuration
Depth of header
Header wall thickness
Tubesheet thickness
Header side wall to tube edge clearance
Header top wall to tube edge clearance
Header bottom wall to tube edge clearance
 AirCooled: Nozzles
The Nozzles screen includes the following inputs:
Nominal pipe size
Actual OD
Actual ID
Wall Thickness
Quantity
Orientation
Length
Flange Thickness
Flange Diameter
Nozzle Flange Rating
Nozzle Flange Type
 AirCooled: Fan
The Fan screen includes the following inputs:
Fan configuration
Fan inlet type
Fan drive type
Fan pitch control
Fan selection method
Fan diameter
Fan speed (rpm)
Fan drive efficiency %
Fan static efficiency %
Use input fan curve
 AirCooled: Fan Curves
The Fan Curves screen includes the following inputs:
Characteristic fan diameter
Characteristic fan speed (rpm)
Reference air density
Volumetric flow rate
Static pressure
Static efficiency
 AirCooled: Fan/Plenum Construction
The Fan/Plenum Construction screen includes the following inputs:
Plenum type
Transition plenum wall length
Transition plenum wall length to fan diameter ratio
Plenum depth
Plenum depth to fan diameter ratio
Fan ring length in airflow direction
Fan ring length in airflow direction to fan diameter ratio
Position of fan ring in plenum
Position of fan ring in plenum to fan ring length ratio
Plenum chamber side to bundle frame X clearance
Plenum chamber side to tubesheet Z clearance
Fan entry lip width in the radial direction
Fan Center offset from plenum center
 AirCooled: Fan Motors
The Fan Motors screen includes the following inputs:
Fan motor orientation
Vertical distance from fan motor shaft end to fan center
Radial distance from fan motor shaft end to fan center
Fan motor body length
Fan motor body diameter
Fan motor shaft length
Fan motor shaft diameter
Length of motor section nearest shaft/motor length
Length of Motor section nearest Shaft
Diameter of motor section nearest shaft/motor diameter
Diameter of Motor section nearest Shaft
Corner radius of near motor section/motor length
Corner radius of nearest Motor
Length of fan motor section/motor length
Length of Motor section farthest from Shaft
Diameter of fan motor section/motor diameter
Diameter of Motor section farthest from Shaft
Corner radius of far motor section/motor length
Corner Radius of farthest Motor
Angle in XZ plane of all but last fan motor
Angle in XZ plane of last fan motor
 AirCooled: Support Structure
The Support Structure screen includes the following inputs:
Bays share support legs
Number of support legs in Z direction
Corner support leg width in the X direction
Corner support leg depth in the Z direction
Ratio of fan entry height above ground to fan diameter
Tubesheet or plenum end to support leg clearance
Sideframe or plenum side to support leg clearance
 AirCooled: Walkways
The Walkways screen includes the following inputs:
Header Walkway
Header walkway width
Header walkway floor to bottom of header distance
Header walkway offset from the headers

Bay walkway
Bay walkway width
Bay walkway offset from expected position

Fan walkway
Fan walkway width
Fan walkway offset from fan centerlines
Fan walkway length beyond centers of end fans

Walkway floor thickness

Walkway railing height
Walkway railing post spacing
Walkway distance below ring fans
 AirCooled: General Screen
The General screen includes the following inputs:
Tube
Header
Tubesheet
Fin Material
Fin Thermal Conductivity
Fin Material Density
Tube Thermal Conductivity
Tube Material Density
Header Density
 AirCooled: Design Code
ASME (American)
CODAP (French)
AD-Merkblätter (German)
EN 13445 (European)
The Design Code is used to tell the program which basic mechanical design
calculations to follow and also to make the heat exchanger specification more
complete.
 AirCooled: Code stamp
No
Yes

Select ‘Yes’ if the box headers for the unit are to be designed and stamped to
the selected pressure vessel design code.
 AirCooled: Material standard
ASME (American)
AFNOR (French)
DIN (German)
JIS (Japanese)
EN (European)

This determines the selection of materials listed in the input for materials of
construction. By default the program uses the standards defined in the
Program Settings under Tools.
 AirCooled: Dimensional standard
ANSI (American)
ISO (International)
DIN (German)

This applies to such things as pipe cylinder dimensions, nozzle flange ratings,
and bolt sizes. DIN also encompasses other construction standards such as
standard tube pitches.
 AirCooled: Design pressure
Used in the mechanical design calculations, the specified design pressure
influences the shell, head, and tubesheet required thicknesses, and therefore
affects the thermal design. If you do not specify a value, the program defaults
to the operating pressure plus 10% rounded up to a logical increment. This is
in gauge pressure, which is one atmosphere less than the equivalent absolute
pressure.
 AirCooled: Vacuum design pressure
By default vacuum design pressure is not calculated for vacuum service.
However, if the heat exchanger is going to operate under a full or partial
vacuum, you should specify a vacuum service design pressure.
The basic mechanical design calculations do not consider external pressure;
therefore, this item will have no effect on the thermal design from the
program.
 AirCooled: Test pressure
This is the pressure at which the manufacturer will test the heat exchanger.
This has no effect on the thermal design, but is included to make the heat
exchanger specification more complete. The default is Code.
 AirCooled: Design temperature
Used in the mechanical design calculations, the design temperatures influence
the shell, head, and tubesheet required thicknesses, and therefore affect the
thermal design and cost. If you do not specify a value, the program defaults
to the highest operating temperature plus 33ºC (60ºF) rounded down to a
logical increment.
 AirCooled: Corrosion allowance
This is included in the thickness calculations for headers and tubesheets, and
therefore has a subtle effect on thermal design. The default is 0.125 in. or 3.2
mm for carbon steel; 0 for other materials.
 AirCooled: Geometry Limits
The Geometry Limits screen includes the following inputs:
Tube Length Increment
Tube Length Minimum / Maximum
Bay Width Minimum / Maximum
Bundle Width Minimum / Maximum
Tube support spacing
Tube rows deep
Tube passes per bundle
Bays per Unit Minimum / Maximum
Bundles per bay
Fans per bay
Tube pass options
 AirCooled: Process Limits
The Process Limits screen includes the following inputs:
Tube side fluid velocity
Outside fluid face velocity
Tube side RhoV2
Fan power maximum
Maximum tube side nozzle pressure loss%
Temperature approach limit
 AirCooled: Optimization Options
The Optimization Options screen includes the following inputs:

Outside Stream Flow Optimization Options

Outlet temperature of x-flow stream
Number of outlet temperatures to evaluate
Optimization criteria
Period of operation to estimate power cost
Power cost per kW-Hr

Optimization Options
Maximum number of design mode iterations
 AirCooled: Process
The Process screen includes the following inputs:
Heat Transfer Options
Vapor heat transfer coefficient
2-phase heat transfer coefficient
Liquid heat transfer coefficient
 AirCooled: Calculation Options
The Calculation Options screen includes the following inputs:
Program Control
Calculation steps per tube
Convergence Control
Number main iterations
Detailed calculation accuracy %
Main iteration accuracy %
 AirCooled: Tube Side
The Tube Side screen includes the following inputs:
Use wet wall desuperheating for condensation applications
Tube side flow distribution
Velocity heads for perforated pass plate pressure drop
Viscosity Method for Two Liquid Phases
 AirCooled: Outside
The Outside screen includes the following inputs:
Outside options
Highfin tube calculation method
Lowfin tube calculation method
Exit pressure recovery coefficient
Fan guard pressure loss coefficient
Fan guard support pressure loss coefficient
Radiation Heat Transfer Options
Include outside radiation heat transfer
Mole fraction of radiating gases in flue gas
 AirCooled: Tube Side Enhancement
The Tube Side Enhancement screen display depends on the Enhancement
Type selected.
 AirCooled: Outside Enhancement
The Outside Enhancement screen includes the following inputs which permit
you to define methods for calculating heat transfer and pressure drop on the
outside of the tube bundle, to be used instead of the methods within the
program. There are options which let you specify two points which the
program will interpolate on a log-log basis (the program assumes a power law
relationship), and there are options whereby you can explicitly supply the
parameters for the power law curves.
Format of input data (options for flow, heat transfer and pressure drop
parameters)
Performance Database Selection
Pt. 1 Flow parameter
Pt. 1 Ho parameter
Pt. 1 PD parameter
Pt. 2 Flow parameter
Pt. 2 Ho parameter
Pt. 2 PD parameter
Ho curve Coefficient
Ho curve Exponent
PD curve Coefficient
PD curve Exponent
Alternatively, you can define a scaling factor to be used to multiply heat
transfer coefficients calculated by the program.
HTC scaling factor
 AirCooled: Inlet Distribution
The Inlet Distribution screen includes the following inputs:
Number of elements across the width of the bundle
Number of elements along the length of the bundle
 AirCooled: Flow
This facility allows you to specify a 2-dimensional Outside Mass Flow and/or
Temperature distribution at the bundle entry.
 AirCooled: Temperature
This facility allows you to specify a 2-dimensional Outside Mass Flow and/or
Temperature distribution at the bundle entry.
 AirCooled: Overall Performance
Process details
Total mass flowrate (X-side & tube side)
Vapor mass flowrate (X-side & tube side)
Liquid mass flowrate (X-side & tube side)
Vapor mass quality (X-side & tube side)
Temperatures (X-side & tube side)
Dew / Bubble point temperatures (X-side & tube side)
Humidity ratio (X-side)
Operating pressures (X-side & tube side)
Operation details
Film coefficients for both sides are based on the bare outside tube area.
Fouling resistances for both sides are based on the bare outside tube area.
Velocity is the highest velocity for any portion of the flow through the bundle
or through the tubes at inlet/outlet.
Pressure drop, allowable is specified in the input as a design constraint.
Pressure drop, calculated is based on the flow, properties and geometry of the
unit.
Performance
Total heat exchanged
Overall coefficients (clean & dirty) based on bare outside tube surface area
Effective mean temperature difference
Effective surface (bare tube)
Effective surface (total) includes finned area
Heat Duty, Effective mean temperature difference and heat balance
Area ratio of actual area to the required area to perform duty
Basic Exchanger Geometry
Bays per unit
Bundles per bay
Tubes per bundle
Rows deep
Tube passes per bay
Fans per bay
Tube OD
Tube thickness
Tube length
Fin OD
Fin thickness
Fin frequency
Resistance Diagram
The resistance diagram appears at the bottom of the main Results Summary.
It shows the thermal resistance between the Outside and Tube Side streams
broken down into five components along the length of a horizontal bar.
The five resistances are:
· Outside stream
· Outside fouling
· Tube wall
· Tube side fouling (Note: This is normalized to the Tube Outside
Diameter)
· Tube side stream
By default, the stream resistances are yellow, the fouling resistances red, and
the wall resistance black.
Stream resistances are derived from the mean stream heat transfer
coefficients given in the Results Summary. Thermal resistances are the
inverse of heat transfer coefficients. The Diagram provides an immediate
indication of the largest resistance in the system, which is the one where an
improvement would have the greatest benefit.
Heat transfer coefficients and fouling resistances can only be compared
against other coefficients and resistances if they are all based on the same
heat transfer area. For that reason, the tube side heat transfer coefficient,
the tube side fouling resistance, the outside heat transfer coefficient and
outside fouling resistance shown on this form are based on the bare outside
tube surface area.
 AirCooled: Resistance Distribution
This screen gives information to help you evaluate the surface area
requirements in the clean, specified fouled/dirty (as given in the input), and
the maximum fouled/dirty conditions.
The clean condition assumes that there is no fouling in the exchanger, in the
new condition. The overall coefficient shown for this case has no fouling
resistance included. Using this clean overall coefficient, the excess surface
area is then calculated.
The specified foul condition summarizes the performance of the exchanger
with the overall coefficient based upon the specified fouling.
The maximum fouled condition is derived by taking the specified fouling
factors and increasing them (if the exchanger is oversurfaced) or decreasing
them (if undersurfaced), proportionately to each other, until there is no over
or under surface.
The distribution of overall resistance allows you to quickly evaluate the
controlling resistance(s). You should look in the "Clean" column to determine
which film coefficient is controlling, then look in the "Spec. Foul" column to
see the effect of the fouling resistances. The difference between the excess
surface in the clean condition and the specified fouled condition is the amount
of surface added for fouling.
You should evaluate the applicability of the specified fouling resistances when
they dictate a large part of the area, say more than 50%. Such fouling
resistances often increase the diameter of the heat exchanger and decrease
the velocities to the point where the level of fouling is self-fulfilling.
Resistance Diagram
The resistance diagram appears at the bottom of the main Results Summary.
It shows the thermal resistance between the Outside and Tube Side streams
broken down into five components along the length of a horizontal bar.
The five resistances are:
· Outside stream
· Outside fouling
· Tube wall
· Tube side fouling (Note: This is normalized to the Tube Outside
Diameter)
· Tube side stream

By default, the stream resistances are yellow, the fouling resistances red, and
the wall resistance black.
Stream resistances are derived from the mean stream heat transfer
coefficients given in the Results Summary. Thermal resistances are the
inverse of heat transfer coefficients. The Diagram provides an immediate
indication of the largest resistance in the system, which is the one where an
improvement would have the greatest benefit.
Heat transfer coefficients and fouling resistances can only be compared
against other coefficients and resistances if they are all based on the same
heat transfer area. For that reason, the tube side heat transfer coefficient,
the tube side fouling resistance, the outside heat transfer coefficient and
outside fouling resistance shown on this form are based on the bare outside
tube surface area.
 AirCooled: Tube Side Composition
The table shows the calculated vapor and liquid compositions at the inlet and
outlet tube side temperatures. The compositions only appear in phase change
applications when component data have been obtained from one of the
available databanks.
 AirCooled: Heat Transfer Coefficients
This output section shows the various components of each film coefficient.
Depending on the application, one or more of the following coefficients are
shown:
· Desuperheating
· Condensing
· Vapor Sensible
· Liquid Sensible
For the Tube Side Stream, the Reynolds number is included so that you can
readily evaluate if the flow is laminar (under 2000), transition (2000-10000),
or turbulent (over 10000).
The fin efficiency factor is used in correcting the outside film thermal
resistance and the outside fouling factor resistance. This correction will also
be reflected in the outside film coefficient.
 AirCooled: Duty Distribution
This output screen summarizes the calculated Heat Loads for the Outside and
for the Tube Side.
 AirCooled: Tube Wall Temperature
The table shows the maximum and minimum values of several temperatures
in each representative tube group used in the calculations. The temperatures
are those on:
· Outside of tube side fouling layer
· Inside surface of tube wall
· Bare tube outside surface (i.e., at fin root)
· Fin tip
· Outside surface of fouling at fin tip
The table also shows the mean metal temperature for each representative
tube group.
 AirCooled: Tube Side
The pressure drop distribution is one of the most important parts of the
output for analysis. You should observe if significant portions or the pressure
drop are expended where there is little or no heat transfer (inlet nozzle,
entering bundle, through bundle, exiting bundle, and outlet nozzle). If too
much pressure drop occurs in a nozzle, consider increasing the nozzle size. If
too much is consumed entering or exiting the bundle, consider increase the
face area of the bundle.
The program determines the dirty pressure drop in the tubes by estimating a
thickness for the fouling, based on the specified tube side fouling resistance,
which decreases the cross-sectional area for flow.
 AirCooled: Outside
This table gives information on the various components of pressure change on
the outside of the tube bundle. Pressure loss contributions arise from flow
over the tube bundle and from ancillary causes such as the fan inlet and
louvers if present. The losses are balanced by the fan static pressure and by
any pressure gain arising from recovery in the plenum of the dynamic head
exhausting form the fan in forced draught.
 AirCooled: hiTRAN Wire Matrix
The following inputs are available when Enhancement Type hiTRAN Wire
Matrix is selected:
Number of Insert Types
Start Pass for hiTRAN Insert
End Pass for hiTRAN Insert
hiTRAN Insert Calculation Type
hiTRAN Part Number
 AirCooled: Setting Plan
The Setting Plan Program provides an approximate setting plan allowing you
to see quickly the exchanger design and the location of the nozzles and the
supports. The drawing is to scale but this program is not intended to provide a
full mechanical design.
 AirCooled: Tube Layout
The Setting Plan/Tube Layout section includes the following screens:
Cost and Weights
 AirCooled: Interval Analysis
The Interval Analysis section provides you with table of values for liquid
properties, vapor properties, performance, heat transfer coefficients and heat
load over the outside temperature ranges.
 AirCooled: Physical Properties
The physical properties used in the calculation are listed on this tab.
 AirCooled: Plots
This tab allows you to create plots from the data displayed in the interval
analysis tables.
Select an X variable and a Y variable to create the required plot.
Various controls are available for zoom-in/out, printing, copying, or saving
the plots.
 AirCooled: Interval Analysis
The Interval Analysis section provides you with table of values for liquid
properties, vapor properties, performance, heat transfer coefficients and heat
load over the tube side temperature ranges.
 AirCooled: Physical Properties
The physical properties used in the calculation are listed on this tab.
 AirCooled: Pressure Change
Flow Pattern Data Nomenclature:
X and Y are coordinates of the flow pattern maps
HF = Horizontal Flow (Taitel and Dukler A.I.C.H.E. Journal Volume 22 Number
1, January 1976)
VD = Vertical Downflow (Golan and Stenning 1969 in HTFS handbook sheets
TM1)
VU = Vertical Upflow (Hewitt and Roberts 1969 in HTFS Handbook sheets
TM1)
ID = Inclined Downflow (use vertical downflow map)
IU = Inclined Upflow (use vertical upflow map)

Flow Regime Names:

ANDSLQ = Annular Dispersed Liquid
ANNULR = Annular
BUBBLE = Bubble
BUBSLG = Bubbly Slug
CHURN = Churn
DISBUB = Dispersed Bubble
INTMIT = Intermittent
OSCLRY = Oscillatory
SLGBUB = Slug and Bubble
STRSMO = Stratified Smooth
STRWAV = Stratified Wavy
WSANLR = Wispy Annular
OUTRNG = Coordinates outside range of map
SNGLIQ = Single Phase Liquid
SNGVAP = Single Phase Vapor
 AirCooled: Plots
This tab allows you to create plots from the data displayed in the interval
analysis tables.
Select an X variable and a Y variable to create the required plot.
Various controls are available for zoom-in/out, printing, copying, or saving
the plots.
 FiredHeater Fuel flow fixed/calculated

This controls the type of calculation to be carried out.

There are two main calculation options and you must select which you want to
use. The choices are:
Simulation (fixed fuel flowrate)
This is for simulation or design checking: You input information about the
firebox geometry, the fuel, the combustion air, the convection section
geometry and the process fluids and the program calculates the heat transfer,
temperature and pressure drop distributions in the heater.
Rating (calculate fuel flowrate)
This is a thermal rating option in which the program calculates the burner fuel
flowrate required to achieve a specified heat load on the firebox process fluid.
You input the same information as for the Simulation option and in addition
you specify the outlet temperature of the firebox process fluid. In this mode
you must provide an initial estimate of the fuel flowrate.) The program
calculates the heat transfer, temperature and pressure drop distributions in
the heater. It then compares the calculated outlet temperature of the process
fluid in the firebox with the specified outlet temperature and iterates on the
burner fuel flowrate until the calculated temperature matches the specified
temperature.
In Rating mode, if you specify multiple fuels, then the proportions of each are
assumed to remain the same, when flowrate is scaled.
Note: You can only use this mode if there is a firebox.
 FiredHeater Draught calculation

This controls the draught calculations, which accurately determines the

pressure drop along the flow path of the combusting / flue gas. To make use
of this calculation, you will need to provide additional information on the
ducting and stack, and on the heights of any convection banks.
The draught calculation is performed after the main heat transfer calculations,
and should not affect the results of these calculations.
Yes – do draught calculation
If you chose this option the program will attempt to carry out a full draught
calculation using all of the additional the information you supply.
If you set only parts of this information some default values will be sets and
as much of the draught calculation as possible will be carried out.
No draught calculation
The calculation will focus on the heat transfer, although it will also calculate
the frictional pressure losses over any convection section tube banks present.
[Input item 015.1]
 FiredHeater Firebox calculation model

This sets the type of model used to simulate the performance of the firebox.
Well-stirred model
Long furnace model

Well-stirred model
This uses only 1 gas zone to model the firebox and the gas within the zone is
considered to be intimately mixed (well stirred) such that the gas
temperature and physical properties are at one value.
This is the program’s default.
If you are automatically zoning the firebox and you do not set the calculation
model the program will assume you wish to use a well stirred model.
Long furnace model
In this model the firebox is divided, vertically, into a number of zones (gas
volumes) and corresponding surface zones. Each zone is considered to be
sufficiently small that the gas temperature and physical properties within
each zone can be considered uniform.
If you are going to zone the firebox yourself and you select a long furnace
model you must take care to set the number of gas zones you are going to
use. If you do not then the program will use a well stirred model instead.
 FiredHeater Number of process streams
Enter the number of process fluid streams in the heater system. This enables
the program to display the correct number of process and properties stream
inputs
The program will allow a total of 10 process streams in the heater. Only 1
stream may be specified for the firebox. A stream may pass through the
heater more than once, for example it may pass through one or more
convection section tube banks before entering the firebox. Many combinations
are possible.
 FiredHeater: Exclude Firebox from Calculation
Use this item to select whether or not you want to exclude the firebox in the
heater from the calculation. The default is No (model the firebox). Specify Yes
if you wish to model convection banks only.

[Input item 102.3]

 FiredHeater Number of convection banks

Enter the number of tube banks in the convection section. The range is 0 to
9.
If you are not modeling a convection section you should enter a value of 0 for
this item.
A tube bank is defined by a number of tube rows within a rectangular duct, all
with the same geometry and layout, and all carrying the same process fluid.
You will need to specify this geometry, and also define the flow path of the
fluid through the bank.
If you have a tube bank that uses two different tube geometries – for
example if the tubes are all finned, except for the first few rows which are
unfinned, then for the purposes of the program, this must be defined as two
separate convection banks. You can indicate that the banks are immediately
adjacent, with no ductwork between.
For convenience, the tube geometry and layout pattern can be defined
separately from tube banks. If all your banks use the same tubes, you define
this tube (as tube type number 1) and then specify that each bank uses tube
type number 1
By default tube banks are numbered in the direction of flue gas flow, but you
can change this if you wish.
[Input item 170.2]
 FiredHeater Flue gas properties

If you are modeling convection banks only, there are two options for
specifying the flue gas properties:
Calculate from fuel and oxidant
Provide as input
If you are modeling a firebox, you must use the first option, and specify one
or more fuels and one or more oxidants. There are a range of options for
doing this
All the options for specifying fuel and oxidant are also available if you are
modeling convection banks only. Although the combustion process is not
modeled, the reaction products are known and these are used to determine
the flue gas properties at any temperature. You will of course have to specify
the inlet temperature to the first convection bank.
The other option for flue gases when specifying convection banks only is to
explicitly specify the flue gas composition and/or properties, using exactly the
same options as are available for specifying the properties of a process
stream. If you select this option, you will see an additional stream “flue gas”
appear at the end of the list of process streams in the properties input
section.
Although the temperature range of the flue gases may not initially be known,
it is possible to specify properties over any appropriately wide temperature
range. These will be interpolated or extrapolated as necessary.
Since the “flue gas” properties can be specified in the same way as any
process stream, it is possible to model the flow of any gas stream over a
convection bank. Any mixture of any gaseous components can be specified.
Note however that the program will not handle condensation or liquid flows,
and that the “flue gas” stream should be cooled by the process streams, not
heated.
 FiredHeater Process stream in firebox tubes

If there is a firebox you must identify which of your process streams flows
through it. Only one of the streams can flow through the firebox.
 FiredHeater Stream name

The program mainly identifies streams by numbers, but you may find it useful
to give each stream a name, particularly if there are several streams. This
name may be supplied with either the process or properties data,
 FiredHeater Total Mass Flow

Enter the total mass flow rate of the process fluid stream. This item must be
supplied, unless the stream inlet and outlet conditions, and heat load are all
specified, so that the corresponding mass flowrate can be back-calculated.
[Input item 202.2]
 FiredHeater Inlet Temperature

You must enter the temperature of stream when it first enters the heater.
For a two-phase stream, you should also be careful that the temperature and
quality you supply are consistent with that in the Physical Property Data
Input, particularly if the boiling is isothermal.
There is an arbitrary default is the ambient air temperature (Ambient
Temperature) plus 100K
[Input item 204.1]
 FiredHeater Outlet Temperature

Enter the temperature of the process fluid stream at outlet from the fired
heater.
This item is only mandatory if the process stream flows through the firebox
and you have requested a burner rating calculation. (Calculate Fuel Flow) If
this is the case the outlet temperature will be used as the target temperature
for the rating calculation. In other cases it is optional, since the program will
calculate stream outlet temperatures. It may be useful, however, to record
the value you expect, or provide the program with an initial estimate
The default is the inlet temperature (Inlet Temperature) plus 100K
[Input item 204.2]
 FiredHeater Inlet Vapor Mass Fraction
Enter the vapor mass fraction (mass quality) at inlet to the heater for this
process fluid stream.
The range is 0.0 to 1.0 and
· All Liquid = 0.0
· All Vapor = 1.0
This item is normally optional, but input is recommended. This item must be
entered when the stream is isothermal two phase at inlet (the temperature
remains constant with changing quality).
[Input item 202.3]
 FiredHeater Outlet Vapor Mass Fraction
Enter required or estimated the vapor mass fraction (mass quality) at outlet
from the heater for this process fluid stream.
This item is normally optional, with stream outlet conditions being derived
from the outlet temperature or heat load, but it is good practice to input a
value if known. The quality is important in defining outlet conditions if the
stream is boiling isothermally (e.g. a single component stream).
 FiredHeater Pressure drop calculation option
Checking (Inlet/Outlet pressures fixed)
Predict outlet pressure
Predict inlet pressure
Predict outlet up to a maximum pressure drop
Predict inlet up to maximum pressure drop

Traditionally, fired heater calculations determine the process stream outlet

pressure for a specified inlet pressure. This is a standard Simulation
calculation, as far as pressure is concerned, and has been used irrespective of
whether the main (heat transfer) calculation was Simulation, Rating /
Checking or Design.
The pressure calculations in FiredHeater provide a number of additional
pressure calculation options. Any option can be used for either stream,
irrespective of the main (heat transfer) calculation type.
The three main alternatives are:
· Calculation of a process stream outlet pressure for a given inlet
(standard option previously in FiredHeater)
· Calculation of process stream inlet pressure for a given outlet
· Checking the process stream pressure change (inlet and outlet both
fixed)
In the Checking calculation, the calculated pressure change is scaled when
determining outlet pressure from inlet, so that the outlet pressure remains at
the initially specified value. The result of such a Checking calculation is a ratio
of the calculated to the specified pressure change.
The benefit of a Checking calculation is that it safeguards against the case in
which the calculated pressure change is much larger than anticipated, maybe
approaching, or even larger than, a specified inlet pressure. This would have
the effect of introducing pressure values into the calculation which are either
impossible or which would lead to other properties which would severely
distort the thermal calculations.
For this reason, two further pressure calculation options are available. These
are to do simulation calculations (outlet from inlet or inlet from outlet) as
long as the pressure changes are small, but should the pressure change
exceed the (user-specified) maximum pressure drop, the calculation reverts
to Checking the pressure change. It reports the ratio of the predicted change
to the maximum value, but never lets calculated pressures fall below the limit
defined by the maximum pressure drop.
 FiredHeater Inlet Pressure

You must enter the (absolute) pressure of the process fluid stream at its inlet
to the fired heater.
This item is required for all calculation modes.
[Input item 204.3]
 FiredHeater Outlet Pressure

Enter the stream outlet pressure. If the inlet pressure, outlet pressure and
estimated pressure drop are all input, they should be self consistent.
If omitted the outlet pressure is determined from the inlet pressure and the
specified (or estimated) pressure loss.
 FiredHeater Maximum Pressure Loss

A value of the maximum permitted pressure loss for a stream may be

entered. If omitted this item is defaulted, using the estimated pressure loss.
This input item does not affect the calculation directly, but is a useful marker,
enabling the results to indicate whether the calculated pressure loss is above
or below the permitted maximum.
 FiredHeater Estimated Pressure Loss

Enter an initial estimate of the pressure loss between inlet and outlet for the
stream. This item is optional. If omitted a default value is set up by the
program.
 FiredHeater Heat Load

Enter an estimated or required value of the heat load for each stream. This
item is not strictly necessary if the inlet and outlet conditions of the stream,
and its flowrate are all specified, but it is useful to input a heat load if known.
The program requires initial values of inlet conditions, outlet conditions heat
load and flowrate. Depending on the calculation type, the main calculation will
then either revise the outlet conditions and heat load for the heater with the
specified firing rate, or predict the firing rate required to deliver the specified
load and outlet conditions.
 FiredHeater Fouling Resistance
Enter the process-side fouling resistance. This is required for the calculation
of the effective (dirty) heat transfer coefficient. The resistance applies
wherever the process fluid flows, in convection banks or the firebox. However
the user can set separate fouling resistances for firebox tube groups and
convections (in Input Data | Heater Geometry | Fire Box | Tube Groups
and Input Data | Heater Geometry | Convection Banks | Tubes
respectively) which will over-ride the value give here.
If omitted, the program assumes that the surface of the tubes is clean, so that
the fouling resistance is 0.0.
 FiredHeater Total mass flow into convection
section

If you are modeling a convection section without a firebox (Number of

fireboxes) enter the total mass flow of the gas at inlet to the convection
section. You will also need to specify the flue gas temperature at inlet.
[Input item 106.1]
 FiredHeater Inlet temperature to convection
section

If you are modeling a convection section without a firebox (Number of

fireboxes) enter the temperature of these gases at inlet to the convection
section. You will also need to specify the total mass flow of the gas at inlet.
 FiredHeater Inlet Pressure (abs)
Air or oxidant pressure at the heater inlet. If there is a firebox present, then
this would be at the inlet to the burner or inlet to the air preheater (if
present). If the firebox was excluded, this would be at the inlet to the
convection section.
 FiredHeater Bridge-wall [firebox exit]
temperature
The Bridge-wall temperature is the temperature at which hot flue gases leave
the firebox.
When the long furnace model is used, the Bridge-wall temperature is not
needed as input. It can be taken to be the calculated temperature of the gas
in the last zone in the firebox.
When the well-stirred (Firebox Calculation Model) model is used, there is a
single zone calculation, with one temperature value of radiating gas
representing the entire firebox. This is normally an overestimate of the
temperature of the hot gases leaving the firebox (the Bridge-wall
temperature). It is therefore possible to input either the Bridge-wall
temperature itself, or to use a correction factor, the Hottel Bridge-wall
Parameter, from which the Bridge-wall temperature can be calculated.
If you know the Bridge-wall temperature, it is best to supply a value. The
corresponding Hottel Bridge-wall Parameter (Hottel Bridge-wall Parameter) is
reported in the output. When you have gathered experience of typical values
of this parameter for your furnace in situations where the Bridge-wall
temperature is known, you can use this information to supply a value to
predict cases where this temperature is not known.
[Input item 107.1]
 FiredHeater Tube gas-side fouling resistance
Enter the gas-side fouling resistance on all tubes. This is required for the
calculation of the overall heat transfer in the firebox and convection banks.
Fouling depends to large extent on the type of fuel burned. Severe fouling
can be expected when burning solid fuel (depending on the type of solid fuel)
and to lesser extent from burning liquid fuels. Fouling when burning gaseous
fuels is normally negligible.
High temperature corrosion results in an oxide layer on tube surfaces. These
oxide layers may constitute significant heat transfer resistance that can be
expressed as a surface fouling resistance.
The value input here applies to all tubes. However, the user can set separate
gas-side fouling resistances for firebox tube groups and convections (in Input
Data | Heater Geometry | Fire Box | Tube Groups and Input Data |
Heater Geometry | Convection Banks | Tubes respectively) which over-
rides the value give here.
If omitted the program assumes that the tube walls are clean, so that the
fouling resistance is 0.0.
 FiredHeater Ambient temperature
Enter the ambient temperature outside the heater. This temperature is used
to calculate heat loss and in draught calculations.
[Input item 102.4]
 FiredHeater Injected steam mass flow

If you are modeling steam injection, set the total mass flow rate of steam that
is injected into the firebox tubes.
The program will use this to calculate the amount of steam that is injected
into each path and the flow rate in each of the tubes after the injection point.
Note: If you have set a steam injection tube you must supply a steam flow
rate.
[Input item 160.2]

See also
Steam Injection
 FiredHeater Steam injection location in firebox

This item identifies whether or not steam is injected into the process stream
flowing through the firebox, and if so, where the injection takes place.
If you are modeling steam injection set the tube set number, at the entry to
which the steam is injected. Tube sets are counted in the direction of process
flow and starting at the inlet tube to the firebox.
If omitted the program will assume that there is no steam injection.
The injection tube can be any of the tube sets in a path and injection is
considered to take place in the U-bend/at the entrance to the first tube in the
set rather than part way along a tube. For cases where steam injection occurs
partway along a set of identical tubes, split that set into two sets, so that
injection can be defined as being at the beginning of the first tube in the
second of these sets.
The maximum number of tube sets in a path is currently 25.
[Input item 160.1]

See also
Steam Injection
 FiredHeater Injected steam pressure

You must enter the (absolute) pressure of the steam injected into the firebox.
If omitted the program will assume that the steam pressure is the same as
the process fluid pressure at the injection point.
[Input item 160.3]

See also
Steam Injection
 FiredHeater Injected steam temperature

Enter the temperature of the steam injected into the firebox.

If omitted the program will assume that the steam temperature is the
saturation temperature at the pressure of the injected steam (Injected steam
pressure).
[Input item 160.4]

See also
Steam Injection
 FiredHeater Injected steam vapor fraction

Enter the vapor mass fraction of the steam injected into the firebox.
The default is a vapor fraction of 1.0 (dry steam), but lower qualities (wet
steam) can be specified.
[Input item 160.5]

See also
Steam Injection
 FiredHeater Steam Injection

You can specify that steam is injected into the process fluid in the firebox.
Steam is assumed to be injected at the entry point to a tube, or set of tubes
in parallel, for example at a U-bend point. You specify the number of this tube
(or group of parallel tubes) along the flow path, in flow sequence (eg at the
start of the 4th tube in each path).
When the steam is injected into multiple tube paths in parallel, it is assumed
that the flow rate and inlet conditions of the steam are the same for each
path. The steam may initially either heat or cool the process stream,
thereafter additional heat from the firebox is used to heat the steam mixed
with the process fluid. See Effect of Steam Injection.
The program uses the Physical Properties Package to determine a revised set
of physical properties, of the stream mixed with steam, for use beyond the
steam injection point. The properties mixing methods used should give
reasonable results in the vapor phase,
To allow for cases where steam is injected into a two-phase stream,
approximation methods are used to model the reduction of the stream dew
point due to the presence of steam, and the vapor fractions below the dew
point. Injected steam (even if not dry when injected) is assumed to be
present in the vapor phase only in the mixed stream.
You will need to specify the flowrate and pressure of the injected steam. You
can also specify the temperature, in case it is superheated, or the vapor mass
quality in case it is wet.
Information on heat inputs to the process stream prior to, at and after
injection is provided in the output.

See also
Effect of Steam Injection
 FiredHeater Effect of Steam Injection

When dry steam is injected to a gas stream, there is initially an input of heat
from the steam to the process gas stream, if the steam is hotter than the gas,
or a loss of heat (negative heat input) if the steam is cooler than the gas.
If the process stream is two phase, then adding dry steam will usually
constitute a heat input to the process stream, because of the evaporation it
induces, even if the temperature of the process stream is slightly reduced.
If the stream is wet, some heat will be used to evaporate the liquid water, so
the heat input to the process stream will be reduced, and may even go
negative.
In all of the above cases, after the injection point, both the steam and the
process fluid with which it is mixed must be heated. For a given heating effect
by the furnace, the effect of the steam will be to reduce the temperature to
which the process fluid is heated.
The program treats the process stream before steam injection and after
injection as separate entities heated by the furnace. Heating of the process
fluid by the furnace before injection, and of the mixed stream after it, both
contribute to the firebox heat balance. However, the heat input (or loss) at
the injection point is entirely separate, and does not figure in the firebox heat
balance.
The steam pressure at injection is used simply in determining the state
(temperature, enthalpy etc) of the steam before injection. No allowance is
made for any momentum transfer or pressure change at the injection point.
The process stream pressure is assumed to be the same after injection as
before.

See also
Steam Injection
 FiredHeater Number of Fuels

You can specify up to four fuels.

The program uses information on the combined fuels and oxidants to predict
the amount of heat released in the firebox(es) and the composition, and
hence properties, of the combusting/flue gases. Allowance is also made for
any steam used to atomize the fuel.
For each fuel you should specify the flowrate, inlet temperature and fuel type.
Further information is needed if you specify a CHONS fuel or a gaseous fuel of
specified composition.
In rating mode the fuel flowrate you initially specify is taken as a first
estimate only. If there are multiple fuels, the relative flows are assumed to
remain constant
 FiredHeater Fuel Name

You can identify each fuel with a unique name that will appear in the results.
 FiredHeater Fuel Type Identifier

Identify the type fuel you wish to use;

Gaseous Fuel
Methane
North Sea Gas
Fuel oil Number 2
Fuel oil Number 4
Fuel oil Number 6
User specified (CHONS fuel)
If you select Gaseous Fuel you will also need to specify the composition of the
fuel.
If you select “CHONS” fuel, you will also have to input the lower calorific
value, specific heat and the amount of the various elements (C, H, O, N, S
{and ash]) in the fuel.
Note: If you are not modeling a firebox this item can be omitted.
[Input item 173.2: 1 = methane, 2 = North Sea Gas, 3 = Fuel oil 2, 4 = Fuel
oil 4, 5 = RFO, 6 = CHONS, 7 = Gaseous, 0 = obsolete]

See also
Fuels (Design Considerations)
 FiredHeater Fuel Flowrate

Enter the mass flowrate of this fuel supplied to the heater

Note 1: the program assumes that all burners in a multi-burner heater are
identical and firing at the samme rate.
Note 2: If you are running the program in the burner rating (Fuel Flow
Setting) mode then enter an initial estimate of the fuel mass flowrate.
Note 3: The fuel flowrate is the main factor in determining the firing rate of
the unit. Neglecting sensible heat in combustion air and the energy of
atomizing steam (with oil fuel), the firing rate is:
[Input item 173.3]
 FiredHeater Fuel Inlet Temperature

Specify the inlet temperature of the fuel that is being burnt. The default is the
ambient (Ambient Temperature) air temperature.
This temperature is used in the calculation of the total energy input to the
firebox.
This parameter can be used to specify fuel preheating which is used to
increase the overall thermal efficiency of the heater. However this, together
with air preheating (Primary Air Temperature) if present, leads to higher
firebox temperatures which may increase NOx emissions.
Additionally Oil fuels are often pre-heated to help vaporize the fuel and so
increase the efficiency of the combustion process. Steam is also often used to
atomize the fuel oil and to assist vaporization. The combustion process is
adversely affected by fuel oils that are insufficiently atomized leading to poor
performance, increased fuel loads and gas-side fouling.
[Input item173.4]
 FiredHeater Atomizing Steam / Fuel Ratio

If you are using steam to atomize a heavy fuel, enter the ratio of the mass of
atomizing steam (if any) to the mass of fuel.
The default is 0.0, to indicate that no atomizing steam is being used.
If there are more than one fuels, this is the ratio to the total flow of all fuels
For oil fuels, steam is often used to atomize the fuel to assist vaporization
which is a necessary step in burning oil fuels.
Typically, steam is supplied at pressures up to 8 bars depending on the
viscosity characteristics of the fuel being burned. Values of ratios in the range
of 0.1 - 0.25 kg steam/kg fuel are common.
You must also supply the atomizing steam temperature

See also:
FiredHeater Liquid Fuels Liquid Fuels
 FiredHeater Atomizing Steam Temperature

Enter the temperature of any steam supplied to atomize the fuel oil.
The default is 150 deg C, corresponding approximately to 5 bar steam.
The steam temperature allows the program to evaluate the steam energy
contributing to the total input energy to the heater. This is normally relatively
small, since only nominal vapor enthalpy change, not latent heat, is relevant
You must also supply the ratio of the mass steam/mass fuel (Ratio Mass
Steam/Mass Fuel)
[Input item 105.5]
 FiredHeater Mass / Molar Composition

Weight flowrate or %
Mole flowrate or %
Indicate whether you wish to specify the composition of a gaseous fuel in
mass or molar terms. The default is mass.
In either case, you can specify flows or fractions or percentages for the
substances present... The values you input are normalized to give fractions
when the program runs.
If you have multiple fuels, take care to specify these data for the correct fuel
[Input item 161.2: 1 = mass, (default) 2 = molar]
 FiredHeater Amount of Component of Gaseous
Fuel

Enter the amount of this component in a gaseous fuel, on a mass or molar

basis as specified.
You can specify flows or fractions or percentages for the substances present.
The values you input are normalized to give fractions.
There is no need to enter zero for substances that are not present.
The list of substances does not distinguish between isomers. For example iso-
butane and n-butane do not appear separately, only “butanes”. Enter the sum
of values for individual isomers in such cases
If you have multiple fuels, take care to specify these data for the correct fuel
[Input items 161.3 – 165.2]
161.3 Methane
161.4 Ethane
161.5 Propane
161.6 Butanes
162.1 Pentanes
162.2 Hexanes
162.3 Cyclohexane
162.4 Benzene
162.5 Ethene (ethylene)
162.6 Propene
163.1 Butenes
163.2 Pentenes
163.3 Butadiene
163.4 Acetylene
163.5 Hydrogen
163.6 Hydrogen sulfide
164.1 Ammonia
164.2 Oxygen
164.3 Nitrogen
164.4 Argon
164.5 Water vapor
164.6 Carbon monoxide
165.1 Carbon dioxide
165.2 Sulfur dioxide
 FiredHeater Gaseous Fuel

If you specify the fuel type as gaseous fuel, you must specify the composition
of your fuel in either mass or molar terms. In either case, you can specify
flows or fractions or percentages for the substances present. The values you
input are normalized to give fractions at run time.

Components in each gaseous fuel can include

Methane
Ethane
Propane
Butanes
Pentanes
Hexanes
Cyclohexane
Benzene
Ethene(ethylene)

Propene
Butenes
Pentenes
Butadiene
Acetylene
Hydrogen
Hydrogen sulfide
Ammonia
Oxygen
Nitrogen
Argon
Water vapor
Carbon monoxide
Carbon dioxide
Sulfur dioxide

To maintain a tractable list of substances, the list does not distinguish

between isomers. For example iso-butane and n-butane do not appear
separately, only “butanes”. The calorific values and other properties of such a
set of isomers are very similar. The program uses an average calorific value
for each set. The amounts of combustion products generated from each of a
set of isomers is of course identical.
 FiredHeater Lower Calorific Value

If you are specifying a CHONS fuel, you must enter the lower calorific value of
the fuel.
Most hydrocarbon fuels have lower calorific values between about 40MJ/kg
(0.017 Mbtu/lb or 9.6 Mcal/kg) for heavy oils and 50MJ/kg (0.021 Mbtu/lb or
12 Mcal/kg) for methane.
Note that HTFS uses the standard definition of M meaning one million (10^6)
in the units MBtu. Practice elsewhere sometimes has MBtu meaning 1000 Btu,
and MMBtu meaning 10^6 Btu.
The lower calorific value is the amount of heat delivered by stochiometric
combustion, with the combustion products being fully cooled, except that any
water vapor produced is assumed to remain in the vapor phase.
Note: This item is not required if you are using one of the standard fuels, only
if you are specifying your own fuel via a CHONS specification
[Input item 174.5, previously 103.5]
 FiredHeater Fuel Specific Heat

For a CHONS fuel, enter the specific heat of the fuel. The default is 2.27
kJ/kgK (0.542Btu/lbF or 0.54 kcal/kg C)
The exact value of this parameter is not usually important, particularly if the
fuel input temperature is close to ambient.
A value up to 10 kJ/kg K (S.I. units), 2.38 Btu/lb F (British units) or 2.38
kcal/kg C (Metric units) may be input.
Note: This item is not required if you are using one of the standard fuels, only
if you are specifying your own fuel via a CHONS specification
[Input item 177.6, previously 103.6]
 FiredHeater Mass / Atomic Amount

For a CHONS fuel you can specify the composition on either a mass or an
atomic basis. This information is usually available on a mass basis, but the
atomic basis can be useful if you happen to know the chemical composition of
what is being burned.
For example suppose you are burning C20H40
On an atomic basis you would specify Amount of Carbon as 20 and amount of
Hydrogen as 40. Setting Carbon to 2 and hydrogen to 4 would be just as
good, since only relative amounts are required, and values are automatically
normalized.
On a mass basis the same fuel would be Carbon 240 Hydrogen 40, or if you
preferred percentage terms Carbon 85.7, Hydrogen 14.3
If your fuel contains ash, only Mass basis should be used
If you have multiple fuels, take care to specify these data for the correct fuel
[Input item 174.3: 1 = mass 2 = atomic]
 FiredHeater Amount of Elements

If you have specified a fuel type of CHONS enter the amount (on a mass or
atomic basis) of the elements in the fuel.
You may find it helpful to enter fractions that sum to 1.0, but this is not
necessary, as the fractions are normalized.

As an example, a residual oil fuel has the following composition:

Carbon 0.886
Hydrogen 0.093
Sulfur 0.0085
Oxygen 0.007
Nitrogen 0.003
Ash 0.0027
_________________
Total 1.00

[Item 104.1 = Carbon, 104.2 = Hydrogen, 104.3 = Nitrogen, 104.4 =

Oxygen, 104.5 = Sulfur, 104.6 = Ash]
 FiredHeater Number of Oxidants

You can specify up to four oxidants, and for each you can specify its
composition. If the oxidant is air, then you simply specify one oxidant, with
one component “dry air” you can specify moist air by adding water as a
second component of the oxidant.
For each oxidant you specify the inlet temperature, and if it is anything but
air, you also specify the composition on a mass or molar basis.

The flow rate of a single oxidant need not specified explicitly: it is derived
from the excess oxygen in the stack (or the excess air) which you specify. If,
however, there are multiple oxidants, then you need to specify a relative flow
for each.
 FiredHeater Percentage of Excess Air

Enter the percentage of excess air (%XS).

This item is important for calculating the amount of air used with the fuel, but
it is only meaningful if the oxidant is air. An alternative, and the only option if
you are using other oxidants as well, is that you specify the amount of oxygen
in the flue gases

Typical excess air values are:

Gas burners

Forced Draught 5% <= %XS <= 10%

Natural Draught 5% <= %XS <= 15%

Oil Burners

Forced Draught 5% <= %XS <= 15%

10% <= %XS <=

Natural Draught
20%

[Input item 105.1]

See also
FiredHeater Burners (Design Considerations) Burners (Design Considerations)
 FiredHeater Percent Oxygen in Flue Gases

Specify the amount of excess oxygen in the flue gases.

This is a percentage, expressed on a mass basis.
It is also expressed on a wet gas basis, meaning that it is a percentage of the
total flue gas mass flow, NOT the flow after cooling and removal of
condensate.
This item is important because it is used to calculate the total oxidant flow.
You do not need to specify this item if your only oxidant is air, and you have
specified an amount of excess air. If you specify both this item and an amount
of excess air, then the amount of excess air will be ignored.
 FiredHeater Oxidant Name

If you have multiple oxidants, it may be helpful to give each a name.

This name will appear in the results.
 FiredHeater Relative Mass Flowrate

This item is only needed if there are multiple oxidants (Oxidants)

The total oxidant flow is not input, but is calculated from the specified excess
oxygen in the flue gases (Excess Oxygen in Flue Gases) or excess air (%
Excess Air)
[Input item 177.3]
 FiredHeater Oxidant Inlet Temperature

Enter the temperature of the combustion air, or other oxidant, at inlet to the
firebox.
The default is the ambient (Ambient Temperature) air temperature.
This temperature is used in the calculation of the total energy input to the
firebox.
The purpose of air preheating is to increase the overall thermal efficiency of
the heater.
In forced draught heaters, air preheating is used to elevate the temperature
of the combustion air supplied to the burner.
The consequences of air preheating include:
Higher firebox gas temperatures can increase NOx emissions.
The pressure drop of the preheater may necessitate the use of forced or
induced draught fans.
[Input item 177.2]

See also;
FiredHeater Air Preheaters (Principal Features) Air Preheaters (Principal
Features)
FiredHeater Air Preheaters (Design Considerations) Air Preheaters (Design
Considerations)
 FiredHeater Mass / Molar Composition (of
oxidant)

Weight flowrate or %
Mole flowrate or %
Indicate whether you wish to specify the composition of an oxidant in mass
(weight) or molar terms. The default is mass.
In either case, you can specify flows or fractions or percentages for the
substances present... The values you input are normalized by the program to
give fractions when it runs.
If you have multiple oxidants, take care to specify these data for the correct
one
[Input item 177.4: 1 = mass, 2 = molar]
 FiredHeater Components of Oxidant

Each oxidant can have its composition specified in terms of a set of

components, namely dry air, oxygen, nitrogen, argon, water vapor and carbon
dioxide
Enter the amount of this component in an oxidant, on a mass or molar basis
as specified.
You can specify flows or fractions or percentages for the substances present...
The values you input are normalized to give fractions when the program runs.
If your oxidant is simply air, simply specify just dry air (enter 1) or dry air
plus water vapor in appropriate proportions. If you have a more complex
oxidant, omit air, and specify the amounts of the other gases present.
If you have multiple oxidants, take care to specify these component data for
the correct one
[Input items 177.5 to 178.6
177.5 Air
177.6 Oxygen
178.1 Nitrogen
178.2 Argon
178.3 Water vapor
178.5 Carbon dioxide
178.6 Sulfur dioxide]
 FiredHeater Fired Heater Type

Enter the basic fired heater configuration, defining whether it is a cylinder or

a box (or cabin); and whether it is a single firebox, or a twin firebox, that is a
pair of fireboxes feeding a single convection section.
[Input item 125.2]
 FiredHeater Firebox - Tube Row Layout
Enter the layout of tubes with the firebox.
For cylindrical fireboxes, you specify here whether there are vertical tubes, or
whether there is a coil, which is treated as the tubes being horizontal.
For cabin or box heaters tubes, you specify here just the location of the tubes.
They can be either refractory backed, that is adjacent to the walls, or there
can be one or two rows of central tubes. You can also specify if there are
multiple internal rows of tubes. These are assumed divide the firebox up into
cells, with the program modeling a representative cell.
For cabin or box heaters tubes, whether the tubes are horizontal or vertical is
specified separately.
For multi-line furnaces, the user must enter the number of tube-lines (in
addition to the number of cells) which allows the user to adjust for various
multi-cell configurations.
The default number of tube lines, Ntline = Ncell + 1 (where Ncell is the
number of furnace cells). This corresponds to a single tube line on each cell
boundary including furnace walls.
The permitted range for Ntline is Ncell – 1 (no wall tubes) to 2 x Ncell (double
tube lines).
In all multi-cell cases, the calculations is based on the assumption of identical
cells with planes of symmetry in the plane of each tube-line. The flow in each
tube-line is adjusted to give the required total flow-rate.

[Input item 132.4]

 FiredHeater Firebox - Height

Enter the internal height of the firebox. This determines the height of the
volume within which heat is radiated from the combusting gases.
Typically the firebox height is 2.5 times the width of a cabin firebox, or 2.5
times the diameter of a cylindrical firebox. With much lower values there is a
risk of the flame being so high as to overheat the roof. With much higher
values the heating at the top of the firebox may be much less than elsewhere.
[Input item 130.3]
 FiredHeater Firebox - Length

Enter the length of the cabin firebox. This is the length of the side along
which (or parallel to which the firebox tubes are located. It helps define the
size of the volume from which heat is radiated from combustion gases.
[Input item 130.2]
 FiredHeater Firebox - Width

Enter the width of the cabin firebox. This is the dimension of the side
perpendicular to the firebox length that is perpendicular to any rows of tubes
in the firebox. It helps define the size of the volume from which heat is
radiated from combustion gases
[Input item 130.4]
 FiredHeater Firebox - Inner Diameter
(cylindrical firebox)

Enter the inner diameter of the cylindrical firebox, that is the inside diameter
of the firebox refractory lining in a cylindrical heater.
[Input item 120.2]
 FiredHeater Number of Cells in Multi-cell
Firebox

If you have selected firebox with multiple lines of internal tubes, dividing the
firebox into cells, you must specify how many cells there are per firebox.
[Input item 116.5]
 FiredHeater Elevation of Floor of Firebox

If you have requested a draught calculation, then the elevation of various

heater components can be specified. All elevations are specified relative to an
arbitrary datum you can choose.
You can enter here the vertical height above the datum height of the bottom
of the firebox. By default this item is zero, meaning that the floor of the
firebox is selected as the datum for measuring elevations.
[Input item 130.5]
 FiredHeater Elevation of Top of Firebox

If you have requested a draught calculation, then the elevation of various

heater components can be specified. All elevations are specified relative to an
arbitrary datum you can choose.
You can enter here the elevation of the top of the firebox. By default this is
calculated using the elevation of the firebox floor and the firebox height. You
can however specify a higher value, indicating that this point, at which the
gases leave the firebox, is higher than the height defining the main volume of
radiating gases. This will have a small effect on the gravitational pressure
change of the firebox gases.
[Input item 130.6]
 FiredHeater Burner Location

You can specify whether the firebox is top-fired or bottom fired.

In the normal, bottom fired case, the flue gases are assumed to flow upwards,
and in the top fired case, the flue gases are assumed to flow downwards.
These assumptions are important with the zone by zone calculation method.
For a well-stirred firebox calculation, the location of the burners is of
secondary importance.
For side firing, use a well stirred calculation, and assuming the flue gases
leave at or near the top of the firebox, select bottom firing.
[Item 116.3, 1 = bottom fired, 2 = top fired]
 FiredHeater Type of Burner

You can select which of the following best describes your burners;
1) Natural draught
2) Forced draught standard
3) Forced draught low NOx.

This item is important if you are performing a zone calculation, and want to
use the internal calculations to determine flame length, and hence the
pattern of heat release along the firebox. You will also need to specify the
number and size of burners, and the type of fuel you are burning.
[Input item 155.4]
 FiredHeater Number of Burners

Enter the total number of burners. This information is used to help estimate
the heat release pattern in the furnace, when a long furnace model is used.
[Input item 116.4]
 FiredHeater Burner Diameter

Enter the diameter of the burner.

For convenience, use the burner exit area. This is used to get the burner
cross sectional area which is needed if the flame length is to be determined
within the program, and to calculate the pressure change following
combustion, as part of a draught calculation.
If you have access to the HTFS Research Network, more information is given
in HTFS Handbook Sheet RM20
[Input item 155.3]
 FiredHeater Number of Paths in a Firebox Tube
Line
Enter the number of parallel paths in each line of tubes in which the process
fluid flows through the firebox. The same number of parallel paths applies to
both main tubes and roof tubes, if any.
The number of tube-lines in each type of firebox is as follows:
· Cylindrical = 1 tube line
· Box (cabin) firebox with refractory backed tubes = 2 tube lines
· Box (cabin) with single row or double row centered tubes = 1 tube line
· For a box (cabin) firebox with multi-tube lines = number of tubes lines is
defined by the input “No. of tube lines in a multi-line firebox ”
Note that each line of tubes is assumed to behave in the same way, as is each
path in each line.
Each tube path consists of a number of tubes in series. These tubes are
defined by the Tube Groups. A Tube Group is a set of tubes the same size in
series. If only one type of tube is used in the firebox, only a single tube group
need be defined. If more than one size of tube is used in the Firebox, a path
will consist of more than one tube group. The program models every tube in a
path separately, however many tube groups there are. There is a maximum
limit, however of fifty tubes in a path.
The assumption that all tube paths behave identically is fine for vertical
tubes, and for the well-stirred firebox model, it is also fine for horizontal
tubes. If the long furnace model is to be used in order to take account of the
variation in heat release and radiant heat flux, it should be noted that vertical
tube paths will always experience identical radiant flux variation. These will
be modeled correctly. If we have horizontal tube paths this variation will only
be modeled correctly if the paths are interspersed.
[Input item 131.1]

Examples of ‘Number of Paths in a Firebox Tube Line’:

Box (cabin) Firebox with 4 Paths - Separated
Box (cabin) Firebox with 4 Paths - Interspersed
Cylindrical Firebox with 6 Paths

API 560 defines the term ‘Pass Stream’ (3.61) – Flow circuit consisting of one
or more tubes in series.
This is related to the Number of paths in a Firebox Tube lines by:
Npass = Npaths x Nlines
Where
Npass = Number of Pass streams
Npaths = Number of Paths in a firebox tube line
Nline = Number of firebox tube lines

See also:
Number of Types of Main Tube (Tube Groups)
 FiredHeater Number of Types of Main Tube
(Tube Groups)
Enter here the number of different types of main (not roof) tubes in the
firebox. Different types normally mean different sizes, but could also mean
different material or wall thickness.
Tube group consists of a set of identical tubes in series. Although different
tube groups normally have different tubes, there is no absolute requirement
for them to be different.
You also need to define the number of parallel paths in each row line) of
tubes. If you add up the numbers of tubes in series in each tube group, and
multiply this sum by the number of paths in a line, you get the number of
tubes in the line.
[Input item 125.2]

See also:
Number of Paths in a Firebox Tube Line
 FiredHeater Orientation of Main Tubes in
Firebox

Specify whether the main tubes (not roof tubes) in the firebox are horizontal
or vertical.
For cylindrical furnaces, the tube layout determines the tube orientation, but
for box/cabin layouts it must be specified.
[Input item 102.2]
 FiredHeater Number of Tube Lines in Multi-cell
Firebox

For multi-cell furnaces the user must enter the number of tube-lines (in
addition to the number of cells) which allows the user to adjust for various
multi-cell configurations.
The default number of tube lines, Ntline = Ncell + 1 (where Ncell is the
number of furnace cells). This corresponds to a single tube line on each cell
boundary including furnace walls.
The permitted range for Ntline is Ncell – 1 (no wall tubes) to 2xNcell (double
tube lines).
In all multi-cell cases the calculations is based on the assumption of identical
cells with planes of symmetry in the plane of each tube-line. The flow in each
tube-line is adjusted to give the required total flow-rate.

[Input item 131.5]

 FiredHeater Firebox - Tube Straight Length

Enter the length of the straight section of a firebox tube. All main tubes are
assumed to be the same length. By default the length is set from the firebox
length(depth) for horizontal tubes, while for vertical tubes the firebox height
is used, together with the height of the first tube to set the default length,
assuming that the tube extends to the top of the firebox.
This item is not needed for coils in cylindrical fireboxes.
Note that you can also specify whether the U-bends are within the firebox or
outside it. If outside it implies the tube straight length must match the
corresponding firebox dimension.
It is important that the length of tubes be set correctly for all calculations.
The location of the tubes within the firebox is important for zone calculations,
but not when the well stirred model is used.
[Input item 802.2]
 FiredHeater Firebox - Height of Lowest Tube
above Firebox Floor

Enter the height from the floor of the firebox to the bottom of the nearest
tube. Use the tube centerline for horizontal tubes, or the bottom of the
straight length for vertical tubes.
Tube location is important for long furnace (zone) calculations, but not with a
well stirred model. A default of 1 ft (0.305m) is set for horizontal tubes,
according to API recommendations.
[Input item 802.1]
 FiredHeater Firebox - Tube to Wall Clearance

Enter the clearance between the centre-line of the main tubes and the firebox
wall. The default setting is 1.5 times the tube diameter, as recommended in
API 560 (September 1995). If the firebox contains tubes of variable diameter
the largest diameter tube will be used to set the clearance.
For cylindrical furnaces with coils, input either this clearance or the coil
diameter and one will be used to set the other, using the specified Firebox
internal diameter.
[Input item 802.3]
 FiredHeater Firebox - Tube U-bend Location

You can identify whether or not the U-bends are within the firebox.
This item should normally be consistent with the tube length and the firebox
dimensions however, if the U-bends are physically within the firebox, and you
specify that they are not, it will simply have the effect of causing heat
transfer to the U-bends to be ignored.
[Input item 802.4]
 FiredHeater Firebox - Tube Layout Angle

If you have a cabin firebox with two rows of horizontal central tubes enter the
layout angle of the tubes. The default is 30 degrees, which means that the
distance between a tube and its nearest neighbor in its own row is the same
as the distance to the nearest tube in the adjacent row.
If the distance between tube centers within a row is D, and the distance
between rows is d, then the layout angle A is defined by tan A = D/(2.d)
The distance ‘D’ is input as the tube centre separation: The layout angle is
used to define the row separation ‘d’.
[Input item 141.1]
 FiredHeater Firebox - Helical Coil Diameter

If you have a helically coiled tube in a cylindrical firebox, enter the diameter
of the coil. This is measured from the centre line of the tubes.
Alternatively you can specify the tube clearance (tube centre to wall distance)
or use the default value of this clearance
[Input item 120.4]
 FiredHeater Firebox - Flow Direction in First
Tube or Overall

If the main tubes in the firebox are vertical, specify whether the flow direction
in the first main tube through which the process fluid flows is up or down.
If the main tubes are horizontal and there is more than one main tube in the
path, enter whether the overall process fluid flow is up or down. If the main
tubes are horizontal and there is only one tube in a path, this input is
ignored.
The main tubes (as opposed to the roof tubes) are the refractory side wall
tubes, or central single or double row of tubes, or multi-line tubes in a multi-
cell firebox.
[Input item 119.4; 1 = up, 2 = down]
 FiredHeater Number of Types of Roof Tube
(tube groups)

Specify the number of different types of roof tube used in the firebox. This
will normally be zero if there are no roof tubes and 1 if there are, but in
principle could be higher if there are multiple different diameters of roof tube
[Input item 125.4]
 FiredHeater Roof Tube Orientation

Enter whether the roof tube centerlines are parallel to the left/right side walls
of the cabin, or parallel to the front/back walls.
All roof tubes are assumed to be horizontal, and to form continuous paths
with the main tubes. If the main tubes are vertical, then it is likely that the
roof tubes will be parallel to the front/back walls of the firebox. If the main
tubes are horizontal, along the exchanger length (side walls) then it is likely
that the roof tubes will be parallel to the main tubes, and thus also to the
left/right walls of the firebox.
[Input item 804.5; 1 = parallel to side walls, 2 = parallel to front/back walls]
 FiredHeater Roof Tube Straight Length

Enter the roof tube straight length. Note that this length can exceed the cabin
length, implying that the U-bends are external to the firebox. There will be no
heat transfer to the length outside the firebox, but process stream pressure
loss there will be accounted for.
[Input item 804.2]
 FiredHeater Roof Tube to Roof Clearance

Enter the distance between the roof tube centerline and the roof.
Note that the program sets a default of 1.5 times the maximum roof tube
outside diameter. This default is displayed once roof tube diameters are input.
[Input item 804.3]
 FiredHeater Roof Tube U-bend Location

Enter whether the roof tube U-bends are inside or outside of the firebox.
Note that the program checks the tube straight length and outside diameter
to see if it is possible for the U-bends to be inside the firebox.
[Input item 804.4; 1 = inside, 2 = outside]
 FiredHeater Roof/Main Tube Flow Sequence

The process fluid in the firebox can enter the roof tubes first and then
through the main tubes, or it can flow through the main tubes and then the
roof tubes. You should specify which.
Note that the Tube Groups for roof and main tubes should each be specified in
the sequence in which the process fluid flows.
[Input item 119.5]
 FiredHeater Firebox - Tube Location
(main/roof)

For each tube group, specify whether the tubes in this Tube Group are main
tubes or roof tubes. Tube groups should be defined in the order in which the
process fluid flows through them
The Tube Dimensions input page shows geometric details of each tube in the
flow path. This input indicates whether the tube in the flow path is a main
tube or a roof tube. The default values are decided by the number of main
tubes in the path, the number of roof tubes in the path, and whether the
process fluid enters the roof tubes before the main tubes or after them.
[Input item 810.6; 1 = main, 2 = roof]
 FiredHeater Firebox - Number of this Size in
Series

A Tube Group is a set of tubes, all of the same size, through which the
process fluid flows in series. You need to enter here the number of such tubes
in series.
[Input Item 835.1]
 FiredHeater Firebox - Tube Material Identifier

Select the tube material from the drop-down list. If the exact material is not
shown, specify something broadly similar. This item is used only to determine
the thermal conductivity of the tube wall.
If you select User Specified, you should go to the input screen for Program
Options / Thermal Analysis / Firebox, and specify the conductivity.
[Input item 835.2]
 FiredHeater: Tube Wall Thermal Conductivity
The tube wall thermal conductivity in the firebox is normally based on
internally stored values for the tube material. If, however, you want to use a
different value, you can identify the tube material as “user specified” and
supply a value for its thermal conductivity here.
[Input item 835.4]
 FiredHeater Firebox - Tube Nominal Bore
(inches)

The program needs to know the tube external diameter and wall thickness of
the tubes in each tube group. You can input these parameters directly, but
you have the alternative of specifying the size of the tube in terms of its pipe
size or nominal bore. This, together with the pipe schedule, is used to
determine the Tube Outside Diameter (OD), wall thickness and Inside
Diameter (ID).
The default setting of User Specified for this item is used when the Tube OD
and Wall Thickness are input directly.
The outside tube diameter corresponding to each nominal bore is given below.

Outside Diameter inches

Nominal Bore
(mm)

1 1.315 (33.40)

1.25 1.660 (42.16)

1.5 1.900 (48.26)

2 2.375 (60.33)

2.5 2.875 (73.03)

3 3.500 (88.90)

3.5 4.000 (101.6)

4 4.500 (114.3)

5 5.563 (141.3)

6 6.625 (168.3)

8 8.625 (219.1)

10 10.75 (273.1)

12 12.75 (323.85)

[Input item 810.1]

 FiredHeater Firebox - Tube Pipe Schedule

If you specify a nominal bore, you should also specify a pipe schedule, so that
the program can determine both the tube outside diameter (OD) and the tube
wall thickness and hence the tube inside diameter (ID).
There is a default of schedule 40: you should check that this is appropriate. If
neither 40 nor 80 is appropriate, input the outside diameter and wall
thickness directly.
The tube inside diameter set for schedule 40 and 80, for each nominal bore,
are given below.

Inside Diameter Inside Diameter

Nominal Outside Diameter
inches (mm) inches (mm)
Bore inches (mm)
(Schedule 40) (Schedule 80)

1 1.315 (33.40) 1.049 (26.64) 0.957 (24.31)

1.25 1.660 (42.16) 1.380 (35.05) 1.278 (32.46)

1.5 1.900 (48.26) 1.610 (40.89) 1.500 (38.10)

2 2.375 (60.33) 2.067 (52.50) 1.939 (49.25)

2.5 2.875 (73.03) 2.469 (62.71) 2.323 (59.00)

3 3.500 (88.90) 3.068 (77.93) 2.900 (73.66)

3.5 4.000 (101.6) 3.548 (90.12) 3.364 (85.44)

4 4.500 (114.3) 4.026 (102.3) 3.826 (97.18)

5 5.563 (141.3) 5.047 (128.2) 4.813 (122.3)

6 6.625 (168.3) 6.065 (154.1) 5.761 (146.3)

8 8.625 (219.1) 7.981 (202.7) 7.625 (193.7)

10 10.75 (273.1) 10.02 (254.5) 9.562 (242.9)

[Input Item 810.5]

 FiredHeater Firebox - Tube Outside Diameter

The tube OD and wall thickness are calculated, and defaults displayed, if you
specify a nominal bore (pipe size) and pipe schedule. You can however
directly input the outside diameter and wall thickness if the default values are
inappropriate.
An outside diameter is required for each tube group. Different groups will
normally have different diameters
[Input item 810.2]
 FiredHeater Firebox - Tube Wall Thickness

The tube OD and wall thickness are calculated, and defaults displayed, if you
specify a nominal bore (pipe size) and pipe schedule. You can however
directly input the outside diameter and wall thickness if the default values are
inappropriate.
A wall thickness is required for each tube group. Different groups will
normally have different diameters and wall thicknesses.
[Input item 810.3]
 FiredHeater Firebox - Tube Spacing
Enter the center-line to center-line distance between adjacent tubes. The
tube separation is effectively the U-bend centre line diameter. This is typically
twice the tube diameter.
The tube separation is important for determining the location of all the tubes
in the firebox and also for determining the U-bend heat transfer area.
If no default separation is displayed and you do not set a value, the program
will select an appropriate value to let the calculations proceed. In some cases,
the program may adjust your value slightly to let calculations proceed. This
can be useful in long furnace (zone) calculations, with horizontal tubes. The
assumption will be made that the tubes are evenly spaced throughout the
available area.
The spacing between tubes in two different tube groups is based on the
average of the two tube diameters.
[Input item 810.4]
 FiredHeater: Tube Side Fouling Resistance
(Firebox)
Enter the tube-side fouling resistance for each tube-group. Separate fouling
factors can be entered for each firebox tube-group and convection banks (on
Heater Geometry | Convection banks | Tubes tab). This is required for
the calculation of the effective (dirty) heat transfer coefficient. The fouling
resistance is based on the inside surface area of the tubes. If omitted, the
program assumes that the surface of the tubes is clean so that the fouling
resistance is 0.0.
 FiredHeater: Gas Side Fouling Resistance
(Firebox)
Enter the gas-side (outside) fouling resistance for each tube-group. Separate
fouling factors can be entered for each firebox tube-group and convection
banks (on Heater Geometry | Convection banks | Tubes tab). This is
required for the calculation of the effective (dirty) heat transfer coefficient.
The fouling resistance is based on the outside surface area of the tubes. If
omitted, the program assumes that the surface of the tubes is clean so that
the fouling resistance is 0.0.
 FiredHeater Total Number of Main Tubes per
Firebox

This item provides you with a check that other firebox information, relating to
tube groups and number of parallel paths has been input correctly. You should
see a default displayed, and should not normally need to enter a different
value.
“Main tubes” means not roof tubes. The sum refers to all lines of tubes in a
firebox, incorporating all the cells in a multi-cell firebox. For twin fireboxes it
refers to a single firebox,
[Input item 803.3]
 FiredHeater Total Number of Roof Tubes per
Firebox

This item provides you with a check that other firebox information, relating to
tube groups and number of parallel paths has been input correctly. You should
see a default displayed, and should not normally need to enter a different
value. Note that this item refers to roof tubes, not main tubes. It is the total
number on both sides of the roof.
It is assumed that there is a direct matching of main and roof tubes, so that
each has the same number of parallel paths.
[Input item 805.3]
 FiredHeater Flue Gas offtake Width

For cabin fireboxes, enter the width of the gas off-take.

[Input item 136.3]
 FiredHeater Flue Gas offtake Length

For cabin fireboxes, you can specify the length of the off-take through which
flue gases are removed. This is normally the same as the length of the firebox
[Input item 136.2]
 FiredHeater Flue Gas Total Exit Area

Enter the size of the flow area through which flue gases are removed. This
exit area can affect the calculated losses in a draught calculation, and also the
radiation losses.
It also defines the remaining area of roof where any roof tubes can be
located. Roof tubes within the gas off-take area cannot be modeled at
present.
[Input item 132.2]
 FiredHeater Tube surface enhancement type

Select the type of enhancement, if any, for the tube:

Plain
Solid fin
Serrated fin
Rectangular studded
Elliptical studded
Lenticular studded
Chamfered studded
Circular studded
Rectangular plate fin

Generally solid helical fins continuously welded to the tube are recommended
in API 560 for fired heater applications. Some standard geometries are
recommended for different fuel firing:

Fuels Fin height Fin thickness Fin frequency

Oil 19 mm 2.54 mm 118 /m

0.75 in 0.1 in 3 /in

Gas 25 mm 1.27 mm 197 /m

1.0 in 0.05 in 5 /in

Although not recommended in API 560, other fin types are used in fired
process heaters with recent wider application of serrated fins.
 FiredHeater Convection Banks - Process Stream
Number in Bank

Enter the number of the process fluid stream that flows through this part of
the heater.
The number should be in the range 1 to 10.
[Input item 148.1 for fireboxes and input item 190.1 for the convection tube
banks.]
 FiredHeater Convection Banks - Stream inflow
from

For streams that flow through multiple convection banks, this input identifies
the previous bank through which this stream flowed. If this is the first bank,
or the stream only flows through one bank, specify “inlet”
[Input item 191.3]
 FiredHeater Convection Banks - Stream outflow
to

For streams that flow through multiple convection banks, this input identifies
the next bank through which this stream flows. It can also specify that the
stream flows next to the firebox. Otherwise, if this is the last bank, or the
stream only flows through one bank, specify “outlet”
[Input item 191.4]
 FiredHeater Convection Banks - Tube number
used in Bank

Convection banks and tubes are numbered separately, so for each bank the
tube used in the bank must be identified. If the same tube geometry is used
in more than one bank, then the tube geometry need only be defined once.
Convection banks are numbered in order of flue gas flow – so bank 1 is
nearest to the firebox. Convection banks can only have one type of tube.
When two different types of tubes are used the bank must be specified as two
separate banks.
 FiredHeater Convection Banks - Number of
Rows of Tubes
Enter the number of rows of tubes in each tube bank. (Convection banks can
only have one type of tube. When two different types of tube are used, the
bank must be treated as two banks)
The Layout diagram screen shows each tube in the tube bank you have
defined, and the flow paths through the bank.
[Input item 180.2]

Examples of Number of Rows of Tubes:

Convection Bank with 4 Paths
Convection Bank with 6 Paths

See also:
Convection Banks - Number of Parallel Paths/Row
Convection Banks - Number of Tubes/Path/Row
 FiredHeater Convection Banks - Number of
Tubes in a Row

Enter the number of tubes in a row. All rows in a bank are assumed to have
the same number of tubes.
The number of tubes in a row must be consistent with the definition of flow
paths through the bank, namely the number of parallel paths in a row and the
number of tubes/row/path
The number of tubes per row is the product of these items.
The Layout diagram screen shows each tube in the tube bank you have
defined, and the flow paths through the bank.
[Input item 180.1]
 FiredHeater Convection Banks - Tube
Orientation in Bank

Set the orientation of the tubes in the tube bank, horizontal or vertical. The
default is horizontal, corresponding to gas upflow in a vertical duct.
For a horizontal duct, the tube orientation can be either horizontal or vertical.
[Item 181.6; 1 = horizontal, 2 = vertical]
 FiredHeater Convection Banks - Flue gas flow
direction

Set the overall flow direction of the hot combustion gases through the tube
bank.
The options are:
Horizontal
Vertical upflow
Vertical downflow
For vertical upflow (or downflow) the tubes must be horizontal.
[Input item 194.1]
 FiredHeater Convection Banks - Tube Length

Enter the length of each tube in the tube bank.

This is the length of tube active in heat transfer (excluding bends, headers,
etc). When finned or studded tubes are used this will normally be the finned
or studded length of the tube.
[Input item 181.4]
 FiredHeater Convection Banks - Row
Arrangement

You must define how the process fluid is distributed between the rows of
tubes (Number of Rows) in the tube bank.
The options are:
Series flow
Parallel flow
The Layout diagram screen shows each tube in the tube bank you have
defined, and the flow paths through the bank.
For parallel flow, the stream temperature at inlet to each row is the same. For
series flow, the flow, you must also specify the overall flow direction. This
would normally be counter-flow meaning that for a bank with vertical gas up-
flow the stream enters at the top row, and exits from the bottom row.
[Input item, 185.1]
 FiredHeater Convection Banks - Stream overall
flow direction

When a steam flows in series through the tubes in a bank, you can specify the
overall flow direction of the process fluid in relation to the gas-side flow.
Countercurrent is most normal, and would apply to a case with vertical upflow
of flue gas, where the process stream enters at the top row, and leaves at the
bottom row.
Co-current flow is when the gas flow and overall flow of process fluid are in
the same direction.
If the stream flows through all of the rows in parallel, this item is not needed.
[Input item 190.3]
 FiredHeater Convection Banks - Flow direction
in first Tube

If the tube bank contains vertical tubes set the flow direction of the process
fluid in the first tube of the bank.
The options are:
Upflow
Downflow
This will affect have some effect on the heat transfer and pressure drop of the
process stream. The effect will probably be fairly small if the flow through the
tube rows is in series, but may be significant if the flow through the tube rows
is parallel.
This item is not relevant to horizontal tubes.
[Input item 191.2 ]
 FiredHeater Convection Banks - Number of
parallel Paths/Row
Enter the number of parallel tube paths per tube row for this tube bank. This
is the number of tubes in the row which the process stream initially enters.
You can also enter the number of tubes per path per row, which is the
number of tubes in series, within the row, through which the steam flows. The
product of the number of parallel paths per row and the number of tubes per
path per row must equal the number of tubes in the row.
[Input item 180.3]

Examples of ‘Number of parallel Paths/Row:

Convection Bank with 4 Paths
Convection Bank with 6 Paths

See also:
Convection Banks - Number of Rows of Tubes
Convection Banks - Number of Tubes/Path/Row
 FiredHeater Convection Banks - Number of
Tubes/Path/Row
Enter the number of tubes per path per row, which is the number of tubes in
series, within the row, through which the steam flows.
You can also enter the number of parallel paths per row for this tube bank
that is the number of tubes in the row which the process stream initially
enters. The product of the number of parallel paths per row, and the number
of tubes per path per row must equal the number of tubes in the row.
The Layout diagram screen shows each tube in the tube bank you have
defined, and the flow paths through the bank.
[Input item 180.4]
Examples of ‘Number of Tubes/Path/Row:
Convection Bank with 4 Paths
Convection Bank with 6 Paths

See also:
Convection Banks - Number of Parallel Paths/Row
Convection Banks - Number of Rows of Tubes
 FiredHeater Convection Banks - Duct Width
(transverse to tubes) and Duct other side
(parallel to tubes)

Two dimensions define the flow cross section of the duct containing a tube
bank, the width (measured transversely to the tubes) and the other side,
(measured along the tubes).
Default values for these parameters are set up, the width from the number of
tubes in a row and the transverse pitch, and the other side from the tube
length. You can modify these defaults if the duct size and tube bank sizes do
not match in exactly this way.
These parameters will have a small effect on the gas side pressure drop and
heat transfer, although it should be noted that significant bypass flows
between the tube bank and the sides of the ducts are not explicitly modeled.
It is assumed that there is corbelling preventing any non-uniform flow past
the tube bank.
[Input item 195.5 = width and 195.3 = other side]
 FiredHeater Convection Banks - Adjoins
preceding Bank

This item is used to specify that the tubes in a bank are immediately adjacent
to the tubes in the preceding bank, in sequence of gas flow. Tube banks are
numbered in the order of gas flow.
A tube bank can have only a single type of tube, and a single process stream.
This item is useful when one physical bank uses two different types of tube, or
has more than one process stream. In such cases it must be modeled as two
or more separate banks.
Heat transfer and pressure drop can be different from the average in the first
few rows of a tube bank, because of entrance effects as the flow distributes
itself within the bank. This flag signifies that such entrance effects should not
apply to this bank.
[Input item 195.6]
 FiredHeater Convection Banks - Tube Material

You can specify the tube material. This allows the thermal conductivity of the
tube wall to be calculated, which will affect the heat transfer in the tube bank.
If you select user-specified, this will give you the opportunity to specify a
(single) thermal conductivity for the tube, on the Program Options, Thermal
Analysis, Flue Gas input screen.
If the exact tube material is not present, using the default, or selecting
something broadly similar, will probably give adequate results.
[Input item 185.1]
 FiredHeater Convection Banks - Tube Nominal
Bore (inches)

You may select the nominal bore (pipe size) of the tube, and the pipe
schedule. If you do the corresponding tube diameter and wall thickness will be
set automatically.
Alternatively, set this item to user specified, and specify the tube diameter
and wall thickness explicitly
Note nominal bore is always specified in inches, whatever units system is
being used.
The outside tube diameter corresponding to each nominal bore is given below.

Outside Diameter inches

Nominal Bore
(mm)

1 1.315 (33.40)

1.25 1.660 (42.16)

1.5 1.900 (48.26)

2 2.375 (60.33)

2.5 2.875 (73.03)

3 3.500 (88.90)

3.5 4.000 (101.6)

4 4.500 (114.3)

5 5.563 (141.3)

6 6.625 (168.3)

8 8.625 (219.1)

10 10.75 (273.1)

[Input item 182.1]

 FiredHeater Convection Banks - Tube Pipe
schedule

If you specify a nominal bore, you should also specify a pipe schedule, so that
the program can determine both the tube outside diameter (OD) and wall
thickness and hence the tube inside diameter (ID).
The tube inner diameter set for schedule 40 and 80, for each nominal bore,
are given below.

Inside Diameter Inside Diameter

Nominal Outside Diameter
inches (mm) inches (mm)
Bore inches (mm)
(Schedule 40) (Schedule 80)

1 1.315 (33.40) 1.049 (26.64) 0.957 (24.31)

1.25 1.660 (42.16) 1.380 (35.05) 1.278 (32.46)

1.5 1.900 (48.26) 1.610 (40.89) 1.500 (38.10)

2 2.375 (60.33) 2.067 (52.50) 1.939 (49.25)

2.5 2.875 (73.03) 2.469 (62.71) 2.323 (59.00)

3 3.500 (88.90) 3.068 (77.93) 2.900 (73.66)

3.5 4.000 (101.6) 3.548 (90.12) 3.364 (85.44)

4 4.500 (114.3) 4.026 (102.3) 3.826 (97.18)

5 5.563 (141.3) 5.047 (128.2) 4.813 (122.3)

6 6.625 (168.3) 6.065 (154.1) 5.761 (146.3)

8 8.625 (219.1) 7.981 (202.7) 7.625 (193.7)

10 10.75 (273.1) 10.02 (254.5) 9.562 (242.9)

[Input Item 182.4]

 FiredHeater Convection Banks - Tube Outside
Diameter

If you specify a pipe size (nominal bore) and pipe schedule, the tube outside
diameter and wall thickness will be defaulted and should not be changed.
Otherwise you should specify both the tube outside diameter (here) and wall
thickness.
[Input item 182.2]
 FiredHeater Convection Banks - Tube Wall
Thickness

If you specify a pipe size (nominal bore) and pipe schedule, the tube outside
diameter and wall thickness will be defaulted and should not be changed.
Otherwise you should specify both the tube wall thickness (here) and outside
diameter.
The tube wall thickness determines the tube inside diameter, which can have
a very significant effect on both pressure drop and heat transfer in the tubes
[Input item 182.3]
 FiredHeater: Convection Banks - Tube Side
Fouling Resistance
Enter the tube-side fouling resistance for each convection bank. Separate
fouling factors can also be entered for each firebox tube-group (on Heater
Geometry | Firebox | Tube Groups tab). This is required for the calculation
of the effective (dirty) heat transfer coefficient. The fouling resistance is
based on the inside surface area of the tubes. If omitted, the program will
assume that the surface of the tubes is clean so that the fouling resistance is
0.0.
 FiredHeater: Convection Banks - Gas Side
Fouling Resistance
Enter the gas-side (outside) fouling resistance for each convection bank.
Separate fouling factors can also be entered for each firebox tube-group (on
Heater Geometry | Firebox | Tube Groups tab). This is required for the
calculation of the effective (dirty) heat transfer coefficient. The fouling
resistance is based on the outside surface area of the tubes. If omitted, the
program will assume that the surface of the tubes is clean so that the fouling
resistance is 0.0.
 FiredHeater Convection Banks - Tube Layout

Enter the layout (pattern) of the tubes in the tube bank. This is defined
relative to the gas flow direction: the options are:
30° (equilateral triangle)
45° (rotated square)
60° (rotated triangle)
90° (inline square)
Rectangular
Other triangular
When choosing one of the standard layouts, i.e. 30, 45, 60 or 90, you must
also specify the tube layout pitch. If you choose either "Rectangular" or
"Other triangular" you must also specify the transverse and longitudinal pitch.
[Input item 181.2, values 1-6 in the order above]
 FiredHeater Convection Banks - Tube Pitch

If you have chosen one of the standard tube layouts, i.e. 30, 45, 60 or 90
degree layouts, set the pitch of the tubes in the bank. This is the distance
between the centers of nearest adjacent tubes.
For a standard layout, the longitudinal and transverse pitches can be
calculated. For other layouts, only these two other pitches should be input.
[Input item 181.4]
 FiredHeater Convection Banks - Transverse
Pitch

If you have selected one of the non-standard tube layouts, i.e. Rectangular or
Other triangular set the transverse pitch for the layout. This is the distance
between the centers of tubes adjacent within a row.
[Input item 182.5]
 FiredHeater Convection Banks - Longitudinal
Pitch

If you have selected one of the non-standard tube layouts, i.e. "Rectangular"
or "Other triangular" enter the longitudinal pitch for the layout. This is the
distance, in the flow direction, between the lines through the tubes centers of
adjacent rows.
[Input item 182.6]
 FiredHeater Convection Banks - Fin Height

For finned tubes, enter the fin height.

It is possible to specify low, high, serrated/cut or rectangular plate fin tubes.
The fin height for a rectangular plate fin tube is slightly different to that for
the other fin types. The following diagram illustrates the fin height for a low
fin tube.

[Input item 183.1]

See also:
Tube Surface Enhancement Type
 FiredHeater Convection Banks - Fin Thickness

For finned tubes, enter the fin thickness.

This parameter will affect the heat transfer and pressure drop performance of
a finned tube bank.

[Input item 183.2]

See also:
Tube Surface Enhancement Type
 FiredHeater Convection Banks - Fin Frequency

Enter the fin frequency (number of fins/unit length of the tube).

This is needed for all fin types but not studs.

[Input item 183.3]

See also:
Tube Surface Enhancement Type
 FiredHeater Convection Banks - Distance to
Plate Fin Inside Edge

If you have specified rectangular plate fin tubes you must enter the distance
from the centre line of the tube to the inside edge of the fin.
[Input item 183.5]
 FiredHeater Convection Banks - Distance to
Plate Fin Outside Edge

If you have specified rectangular plate fin tubes you must enter the distance
from the centre line of the tube to the outside edge of the fin.
[Input item 183.6]
 FiredHeater Convection Banks - Stud Height

Enter the height of the studs on a studded tube.

Some standard geometries are recommended for different fuel firing:

Fuels Stud height Stud thickness

Oil or Gas 25 mm (1.0 inch) 13 mm (0.5 inch)

You should also specify the stud width, the number of studs in each
circumferential row of studs, the stud row frequency and the stud thermal
conductivity.
The following pictures illustrate the dimensions you must set to define a
studded tube.
Rectangular studded
Elliptical studded
Lenticular studded
Chamfered studded
Circular studded
[Input item 184.1]
 FiredHeater Convection Banks - Stud Thickness

Enter the stud thickness, measured axially along the tube. For studs of
circular cross section the stud thickness is equivalent to the stud diameter.
For other studs the width (measured around the tube circumference) must
also be defined.
This parameter affects the gas side heat transfer and pressure drop.
A typical size of stud has a stud thickness (diameter) of 0.5 in (13 mm) and
stud height of 1 in (25 mm)
You should also specify the stud width, the number of studs in each
circumferential row of studs, the stud row frequency and the stud thermal
conductivity.
The following pictures illustrate the dimensions you must set to define a
studded tube.
Rectangular studded
Elliptical studded
Lenticular studded
Chamfered studded
Circular studded
[Input item 184.2]
 FiredHeater Convection Banks - Stud Width

Enter the stud width, measured circumferentially around the tube. For studs
of circular cross section there is no need to specify this dimension, since it is
the same as the “thickness” of the stud, measured axially along the tube.
You should also specify the stud height, thickness, the stud row frequency,
the number of studs in each circumferential row and the stud thermal
conductivity.
The following pictures illustrate the dimensions you must set to define a
studded tube.
Rectangular studded
Elliptical studded
Lenticular studded
Chamfered studded
Circular studded
[Input item 184.3]
 FiredHeater Convection Banks - Stud Row
Frequency

Studs are often attached in circumferential rows, or “crowns” around the

tube. Enter here the stud row frequency, that is, the number of
circumferential rows of studs per unit axial length of tube.
[Input item 184.4]
 FiredHeater Convection Banks - Number of
Studs/Row

Studs are often attached in circumferential rows, or “crowns” around the

tube.
Enter here the number of studs in each circumferential row around the tube.
[Input item 184.5]
 FiredHeater Convection Banks - Fin or Stud
Material

Enter the fin or stud material. This is used to determine the thermal
conductivity. If you select User Specified, you can input thermal conductivity
explicitly under Methods / Thermal Analysis (or accept the default
conductivity set there.
[Input item 185.3]
 FiredHeater Type of Flue/Stack

Select one of the following options:

None
Stack only
Duct, air preheater, stack

None
A flue system is not modeled. This option should be used if you do not require
draught (gas-side pressure change) calculations to be carried out in the flue
system.
Stack only
This is a flue system in which the combustion product gases (flue gases) leave
the firebox or convection section if present, flow through a vertical stack and
exhaust to atmosphere.
Duct, air preheater, stack
This is a flue system in which the combustion product gases (flue gases) leave
the firebox, or convection section if present, and flow through additional
ducting before entering a vertical stack and exhausting to atmosphere. This
type of system is often used where combustion air preheating, using the flue
gases to provide heat, is employed.

See also:
Fans, Stacks, Ducting and Dampers (Principal Features)
Exhaust Gas Temperature (Design Considerations)
[Input item 196.1; 0 = none, 1 = stack only, 2 = duct etc.]
 FiredHeater Stack Diameter at Bottom
You can input the diameter of the stack the bottom of the stack, where flue
gases enter, and at the top of the stack where they exit to atmosphere.
The default diameter at the bottom of the stack is determined from the size of
the last convection bank. The top diameter defaults to be the same as at the
bottom.
If the two diameters are different you can specify a transition region over
which the stack diameter tapers from one diameter to the other. Before and
after such a transition, the stack diameter is assumed to be constant.
If you have a stack that is not of circular cross section set the stack diameter
at the start to be the equivalent hydraulic diameter (dh) at the start of your
system such that
dh = 4 x flow area/ perimeter.
The diameter at the top of the stack is used to calculate the exit velocity of
the flue gas from the stack. It is good design practice to maintain a
reasonably high flue gas exit velocity from the stack, to avoid ingress of cold
air. If you have access to the HTFS Research Network, more information is
given in Handbook Sheet RM10, which recommends 13 m/s.
Stack parameters need only be specified if you require a draught calculation.
[Input item 196.4 (diameter at bottom), 197.3 (diameter at top)]
 FiredHeater Stack Diameter at Top

You can input the diameter of the stack the bottom of the stack, where flue
gases enter, and at the top of the stack where they exit to atmosphere.
The default diameter at the bottom of the stack is determined from the size of
the last convection bank. The top diameter defaults to be the same as at the
bottom.
If the two diameters are different you can specify a transition region over
which the stack diameter tapers from one diameter to the other. Before and
after such a transition, the stack diameter is assumed to be constant.
If you have a stack that is not of circular cross section set the stack diameter
at the start to be the equivalent hydraulic diameter (dh) at the start of your
system such that
dh = 4 x flow area/ perimeter.
The diameter at the top of the stack is used to calculate the exit velocity of
the flue gas from the stack. It is good design practice to maintain a
reasonably high flue gas exit velocity from the stack, to avoid ingress of cold
air. If you have access to the HTFS Research Network, more information is
given in Handbook Sheet RM10, which recommends 13 m/s.
Stack parameters need only be specified if you require a draught calculation
[Input item 196.4 (diameter at bottom), 197.3 (diameter at top)]
 FiredHeater Height to Bottom of Stack

Enter the vertical height/elevation of the start (bottom) of the stack

All elevations of parts of the heater system are defined relative some datum
level of your own choosing.
Note: This parameter need only be specified if you require a draught
calculation.
[Input item 196.2]
 FiredHeater Height to Top of Stack

Enter the vertical height/elevation of the end (top) of the stack.

All elevations of parts of the heater system are defined relative some datum
level of your own choosing.
Note: This parameter need only be specified if you require a draught
calculation.
[Input item 196.3]
 FiredHeater Height to Bottom of Transition
Region

If you specify that the diameters at the top and bottom of the stack are
different, then you can specify the extent and location of the transition region
between the two diameters. Enter the heights (elevations) to the bottom and
top of this region.
All elevations of parts of the heater system are defined relative some datum
level of your own choosing.
If the two heights are the same, an abrupt transition is assumed. If they are
different, a smooth tapering in the transition region is assumed.
[Input items 197.1 (bottom) and 197.2 (top)]
 FiredHeater Height to Top of Transition Region

If you specify that the diameters at the top and bottom of the stack are
different, then you can specify the extent and location of the transition region
between the two diameters. Enter the heights (elevations) to the bottom and
top of this region.
All elevations of parts of the heater system are defined relative some datum
level of your own choosing.
If the two heights are the same, an abrupt transition is assumed. If they are
different, a smooth tapering in the transition region is assumed.
[Input items 197.1 (bottom) and 197.2 (top)]
 FiredHeater Height of Damper in Stack

Enter the vertical height/elevation of the damper in the stack. Like all
elevations of parts of the heater system, this is defined relative the datum
level of your own choosing.
This height is needed so that the program can calculate the cross sectional
area of the stack where the damper is located. This area is used with the flue
gas mass flow and damper pressure loss coefficient to calculate the pressure
drop across the damper.
It is important that you also specify the loss coefficient if you want the effect
of a partially closed damper to be taken into account in the draught
calculation.
[Input item 196.5]
 FiredHeater Diameter of Flue Duct

You can specify a diameter for the flue duct between the last convection bank
(or firebox if there are no convection banks) and the stack.
If you specify a diameter, circular ducting is assumed and input for the width
and depth of the duct is ignored. If you do not specify a diameter, then a
rectangular flue duct is assumed.
Duct dimensions are only needed if you specify a draught calculation, and
select a stack type that includes ducting, rather than being “stack only”.
[Input item 198.4]
 FiredHeater Width of Flue Duct

You can specify a width for the flue duct between the last convection bank (or
firebox if there are no convection banks) and the stack.
A rectangular flue duct is assumed, unless you specify a duct diameter. The
default dimension is normally taken from the width of the last convection
bank
Duct dimensions are only needed if you specify a draught calculation, and
select a stack type that includes ducting, rather than being “stack only”.
[Input item 198.5]
 FiredHeater Depth of Flue Duct

You can specify a depth for the flue duct between the last convection bank (or
firebox if there are no convection banks) and the stack.
A rectangular flue duct is assumed, unless you specify a duct diameter. The
default dimension is normally taken from the depth of the last convection
bank.
Duct dimensions are only needed if you specify a draught calculation, and
select a stack type that includes ducting, rather than being “stack only”.
[Input item 198.6]
 FiredHeater HTC by HTFS or API Methods

You can select the method for calculating the process side heat transfer
coefficient for each process stream. The default is the HTFS method.
The API method is based on API Recommended Practice 530.
If you have access to the HTFS Research Network, you can find the HTFS
methods for single phase in-tube heat transfer, and for boiling in tubes
described in Handbook Sheets and Design Reports. These are the standard
HTFS methods for in-tube heat transfer used in Tasc+ and other HTFS
programs, and cover a wide range of process fluids and process conditions.
For helical coils in cylindrical furnaces, special adaptations are used, as
described in Handbook Sheets SM12 and BM3 for single phase and boiling
respectively.
The API method is summarized in HTFS Design Report 60. They should be
used only when you are confident that they are applicable to your particular
process fluid.
[Input item 202.6 1 = HTFS, 2 = API]
 FiredHeater Liquid Phase HTC

The program will calculate the heat transfer coefficient for each stream.
Coefficients depend on stream mass flux and physical properties, and on the
tube internal diameter and wall temperature, and will vary as the stream
passes through the heater.
If you have reason to believe that the program calculated values of heat
transfer coefficient are inappropriate, in special circumstances you may wish
to replace the stream with a specified fixed value. You can do this separately
for liquid, two-phase (boiling) and vapor heat transfer.
[Input item 206.1-3]
 FiredHeater Two Phase HTC

The program will calculate the heat transfer coefficient for each stream.
Coefficients depend on stream mass flux and physical properties, and on the
tube internal diameter and wall temperature, and will vary as the stream
passes through the heater.
If you have reason to believe that the program calculated values of heat
transfer coefficient are inappropriate, in special circumstances you may wish
to replace the stream with a specified fixed value. You can do this separately
for liquid, two-phase (boiling) and vapor heat transfer.
[Input item 206.1-3]
 FiredHeater Vapor Phase HTC

The program will calculate the heat transfer coefficient for each stream.
Coefficients depend on stream mass flux and physical properties, and on the
tube internal diameter and wall temperature, and will vary as the stream
passes through the heater.
If you have reason to believe that the program calculated values of heat
transfer coefficient are inappropriate, in special circumstances you may wish
to replace the stream with a specified fixed value. You can do this separately
for liquid, two-phase (boiling) and vapor heat transfer.
[Input item 206.1-3]
 FiredHeater Liquid Phase HTC multiplier

If you have reason to believe that the program calculated values of heat
transfer coefficient are inappropriate, you may wish to scale them to achieve
higher or lower values. Multipliers above unity give higher coefficients. You
can select separate scaling for the liquid, two-phase (boiling) and vapor
values if you wish.
[Input item 206.4-6]
 FiredHeater Two Phase HTC multiplier

If you have reason to believe that the program calculated values of heat
transfer coefficient are inappropriate, you may wish to scale them to achieve
higher or lower values. Multipliers above unity give higher coefficients. You
can select separate scaling for the liquid, two-phase (boiling) and vapor
values if you wish.
[Input item 206.4-6]
 FiredHeater Vapor Phase HTC multiplier

If you have reason to believe that the program calculated values of heat
transfer coefficient are inappropriate, you may wish to scale them to achieve
higher or lower values. Multipliers above unity give higher coefficients. You
can select separate scaling for the liquid, two-phase (boiling) and vapor
values if you wish.
[Input item 206.4-6]
 FiredHeater Hottel Bridge-wall Parameter
The Hottel Bridge-wall Parameter provides a basis for predicting the Bridge-
wall Temperature of a firebox when using the well-stirred model (Firebox
Calculation Model).
If you know the Bridge-wall temperature, then enter that temperature and
ignore this parameter.
If you do not know the Bridge-wall temperature, then either leave this
parameter set to its default value (0.08, which is a typical value based on
experience with operational heaters), or explicitly specify a value. For
example, you might have obtained a value by running the program on similar
cases where the Bridge-wall temperature was known.
If you enter a value of zero, you will revert to the simple version of the well-
stirred model, in which the gases leaving the firebox (which define the bridge
wall temperature) are at the mean gas temperature used for radiation
calculations.
The Hottel Bridge-wall Parameter appears in a correction to the simple well
stirred model, developed by Hottel. It is the ratio of the sensible heat change
between the well-stirred temperature and the bridge-wall temperature to the
total heat delivered to the tubes and walls of the firebox.
[Input item 107.2]
 FiredHeater Tube Gas-side Heat Transfer
Coefficient

Enter the gas-side heat transfer coefficient for the outside of the firebox
tubes.
The complex flow field in the firebox makes it very difficult to predict this
parameter from a convective heat transfer model. It is normal design practice
to assume a uniform coefficient of about 12 W/m2 K over all of the firebox
tube surfaces, and use this with the temperature difference between the hot
radiating gas and the tube to predict convective heat transfer.
Since most of the heat transfer to the firebox tubes is radiative, rather than
convective, an approximate value of this heat transfer coefficient is normally
adequate.
[Input item147.3]
 FiredHeater Tube Wall Thermal Conductivity
The tube wall thermal conductivity in each convection bank is normally based
on internally stored values for the tube material. If, however, you want to use
a different value, you can identify the tube material as “user specified” and
supply a value for its thermal conductivity here.
[Input item 187.1]
 FiredHeater Peak Tube Temperature Calculation
Method
Both methods for calculating peak tube temperature and heat flux are based
on the following equation described in API 530, Appendix C.
qm= FcFLFTqa + qc

qm = Maximum heat flux (net) at tube surface

qa = Average radiant heat flux (net) at tube surface
qc = Average convective heat flux (net) at tube surface
Fc = Factor accounting for circumferential heat flux variations
FL = Factor accounting for longitudinal heat flux variations
FT = Factor accounting for effect of tube temperature on radiant heat flux

Fc allows for the fact that metal at the front of the tube is more exposed to
radiation than metal at the back or side because it is not shielded by other
tubes. FiredHeater will calculate a value of Fc based on the charts in API 530
or alternatively it can be set by the user (see Circumferential heat flux
variation). FL allows for longitudinal variations – in FiredHeater, it defaults to
1.0 but can be set by the user for variations of gas temperature in the firebox
(see Longitudinal heat flux variation).
The difference between the two calculation methods focuses on the valuation
of FT. In Fixed heat flux ratio, the value of FT is assumed to be 1.0. This is
the calculation option used prior to FiredHeater version 7.1.
Fc and FL determine variations in the radiant heat flux arriving at the tube
wall. However, the net heat transfer through the tube wall should be adjusted
for tube temperature because hotter tube will radiate back more strongly. In
the Adjusted heat flux ratio calculation option, the value of FT is adjusted
to allow for variation in the tube temperature by

FT = (Tg4 - Tm4)/(Tg4 – Ta4)

Tg = Effective gas temperature radiating to tube surface (K)

Tm = Tube surface temperature at point under consideration (K)
Ta = Average tube temperature in tube section (K)

At the point of maximum heat flux, FT will be less than 1 (Tm > Ta). The
Adjusted heat flux ratio was first available in version 7.1 of FiredHeater.
This method is more theoretically sound and generally gives lower predictions
of peak heat flux and tube temperature.
 FiredHeater Longitudinal Heat Flux Variation

After the energy balance calculation has converged the results are used to
calculate a firebox tube maximum heat flux and corresponding tube
temperature profile based on the method given in Appendix C of API Standard
530 (1996).
This method uses a longitudinal heat flux variation factor, ‘FL’, to allow for
variations in the radiant heat flux resulting from proximity to burners and
variations in the radiant firebox and bulk fluid temperatures.
Note: ‘FL’ is not easy to quantify and values between 1.0 and 1.5 are most
often used. In a firebox that has a very uniform distribution of heat flux, a
value of 1.0 may be appropriate. Values greater than 1.5 may be appropriate
in a firebox that has an extremely uneven distribution of heat flux (for
example, a long or tall, narrow firebox with burners in one end only).
When using the Long Furnace Model (LFM), in which the firebox is divided
into several zones and the gas and surface temperatures and heat flux
calculated for each zone, the program takes into account in a consistent way
variations in the longitudinal heat flux. In this situation a value of 1.0 for ‘FL’
is the most appropriate value.
[Input item 147.5]
 FiredHeater Circumferential Heat Flux Variation

After the energy balance calculation has converged, the results are used to
calculate a firebox tube maximum heat flux and corresponding tube
temperature profile based on the method given in Appendix C of API Standard
530 (1996).
This method uses a circumferential heat flux variation factor, ‘FC’, to allow for
variations in the radiant heat flux produced by shadings of other tubes or
from placement of the tubes next to a wall.
Either enter an appropriate value of ‘FC’, in the range 1.0 to 4.5, for your
firebox or leave it blank so that the program will calculate a value for you.
In API 530 ‘FC’ is given in a figure for various tube arrangements (refractory-
backed or central tubes, and single or double row of tubes) as a function of
the ratio of the tube spacing to the tube outside diameter. For use in the
program, these curves have been fitted with low-order polynomials. ‘FC’ is
then calculated for the appropriate tube arrangement at the ratio of the tube
spacing to the tube outside diameter.
[Input item 147.4]
 FiredHeater Tube Wall Emissivity

A default emissivity is available for all firebox tubes. You can however set
different emissivities for different tube groups if you wish. This could be used
to represent the effect of ceramic coatings on certain tubes, or of different
surface properties at different points in the firebox.
[Input item 835.3]
 FiredHeater Firebox Wall Emissivity

Enter the emissivity of the firebox wall, if you want to override the default
value shown. This is required for the calculation of the radiative heat transfer
to and from the firebox walls.
Normally a refractory material is used to line the firebox. This material will be
selected to have a low thermal conductivity and emissivity to minimize heat
loss from the firebox. It may also be required to have sufficient mechanical
strength to withstand high gas velocities in certain regions of the firebox.
If you want to change this item, consult the material manufacturer, or a data
sheet for the material used for the interior of your firebox wall, to obtain the
most appropriate emissivity. If you have access to the HTFS Research
Network, HTFS Handbook Sheet RD1 contains a list of emissivities for
common refractory and furnace materials (generic rather than manufacturer
named brands).
[Input Item150.1]
 FiredHeater Grey Gas Emissivity Model
Select the grey gas model to calculate the gas emissivity and absorptivity in
the firebox.
There are two choices:
· 2-grey gas model with user specified coefficients – This model has
been retained for backward compatibility with Aspen EDR Versions prior to
Release 7.2.
· 4-grey gas model with coefficients calculated from the
composition of the flue gas – This model gives significantly improved
predictions of gas emissivity especially for moderate to large fireboxes and is
now recommended for all cases.
If you have access to the HTFS Research Network, more information and data
is given in HTFS Handbook Sheet RD2 and in the HTFS design report for the
FIHR program DR33 which used the same methods as FiredHeater.
Coefficients for the 4-gas model are given in DR33 Part 2.
Note: The following inputs only apply to the 2-grey gas model:
Amplitude of Grey Gases
Absorption of First Grey Gas
Absorption of Second Grey Gas
 FiredHeater Amplitude of Grey Gases

Fired Heater uses a “two grey gas” model for calculating radiation heat
transfer from radiating gas to each wall and tube surface, and from every
surface to every other surface through the gas. Default parameters are
normally used for all these calculations. The facility is provided, however, for
you to override the defaults.
Only the grey gas amplitude for the first gas need be supplied. The maximum
value is 1.0 and the sum of the amplitudes of the two grey gases must be
unity. Amplitude zero implies a clear gas that does not interact with radiation.
If you have access to the HTFS Research Network, more information and data
is given in HTFS Handbook Sheet RD2 and in the HTFS design report for the
FIHR program which used the same methods as FiredHeater.
[Input item 115.2]
 FiredHeater Absorption of First Grey Gas

Fired Heater uses a “two grey gas” model for calculating radiation heat
transfer from radiating gas to each wall and tube surface, and from every
surface to every other surface through the gas. Default parameters are
normally used for all these calculations. The facility is provided, however, for
you to override the defaults.
This input relates to the first grey gas, and is used in conjunction with the
radiation beam length between surfaces, and the amplitude of the (first) grey
gas, as input or defaulted.
A coefficient up to 100/m (30.84/ft) may be set. Larger values than the
default could be used to approximate the effect of soot or other particles on
radiation.
If you have access to the HTFS Research Network, more information and data
is given in HTFS Handbook Sheet RD2, and in the HTFS design report for the
FIHR program which used the same methods as FiredHeater.
[Input item 115.3]
 FiredHeater Absorption of Second Grey Gas

FiredHeater uses a “two grey gas” model for calculating radiation heat
transfer from radiating gas to each wall and tube surface and from every
surface to every other surface through the gas. Default parameters are
normally used for all these calculations. The facility is provided, however, for
you to override the defaults.
This input relates to the second grey gas, and is used in conjunction with the
radiation beam length between surfaces, and the amplitude of the second
grey gas, which is determined from the input for the amplitude of the (first)
grey gas, which can be input or defaulted.
A coefficient up to 100/m (30.84/ft) may be set. Larger values than the
default could be used to approximate the effect of soot or other particles on
radiation.
If you have access to the HTFS Research Network, more information and data
is given in HTFS Handbook Sheet RD2, and in the HTFS design report for the
FIHR program which used the same methods as FiredHeater.
[Input item 115.4]
 FiredHeater Specify Wall Heat Loss Fraction

You can select whether or not you want to specify the heat loss that occurs
through the firebox walls. If you do not specify it, it will be calculated.
It is simplest to specify this loss as a fraction of the firebox heat release. The
alternative is to calculate it by supplying information about conduction
through the firebox wall, and heat transfer on the inner and outer surfaces of
the wall. Although defaults are provided for all these parameters, you should
check carefully that they are appropriate.
[Input item 150.3]
 FiredHeater Wall Heat Loss Fraction

Enter the fraction of the total combustion heat release in the firebox that is
lost through the firebox wall.
A value 0.02 means that 2% of the heat input to the firebox is lost through
its walls.
[Input item150.4]
 FiredHeater Firebox Wall Thermal Conductivity

Enter the thermal conductivity of the firebox wall, if you have asked for the
heat loss through the firebox wall to be calculated. A simple default is
provided, but you are advised to input a more correct value.
The firebox wall is usually a composite with refractory lining, inner casing,
external insulation and external cladding and normally the heat transfer
resistance of the refractory lining and any external insulation will dominate.
You should input an effective thermal conductivity for the whole composite
layer, to go with the complete composite thickness.
[Input item 151.2]
 FiredHeater Firebox Wall Thickness

Enter the thickness of the firebox wall, if you have asked for the losses
through the firebox wall to be calculated. A simple default is provided, but you
are advised to input a more correct value.
The firebox wall is usually a composite with refractory lining, inner casing,
external insulation and external cladding and normally the heat transfer
resistance of the refractory lining and any external insulation will dominate.
You will need to calculate an effective thermal conductivity, and a total
thickness for the whole composite layer.
[Input item 151.1]
 FiredHeater Firebox Inner Wall Heat Transfer
Coefficient

Enter the gas-side heat transfer coefficient for the inner side of the firebox
wall. This value is used for internal heat transfer calculations, as well as for
calculating wall losses. Most heat transfer from the hot gases to the wall is
usually by radiation. The heat transfer coefficient is used to account for
additional convective heat transfer, and its exact value is often not too
important.
[Input item 150.2]
 FiredHeater Firebox Outer Wall Heat Transfer
Coefficient

Enter the gas-side heat transfer coefficient for the outer side of the firebox
wall, if you have asked for wall losses to be calculated.
A simple default is provided. A higher value may be specified if there is good,
wind-assisted, heat transfer on the outside of the firebox, or if you want to
ensure that values of the wall losses are dominated by the wall insulation.
Inputting a low coefficient may give an unrealistically low value for wall
losses.
[Input item 151.4]
 FiredHeater Direct Radiation to the Shield
Tubes

The shield tubes are the first rows of convection bank tubes encountered by
the flue gases after leaving the firebox. If these are in line of sight from the
firebox, radiation from the firebox will impinge on them directly. There may
also be radiation from the hot flue gases themselves, after they have left the
firebox, and from the flue walls. The combination of effects can be complex:
this input item lets you model two extremes, either all of the radiation leaving
the firebox along with the flue gases impinges on the shield tubes, or none of
it does.
The amount of radiation from the firebox is normally calculated by the
program. If, however, you are only doing a calculation for convection banks,
not a firebox, you can specify an estimate of the amount of radiation hitting
the shield tubes.
You can also specify the fraction of the radiation load which is absorbed by the
first second and third rows of tubes.
[Input item 119.1]
 FiredHeater Radiation Load on Shield Tubes

This input item is only needed if you are only modeling convection banks, not
a firebox, but wish to allow for firebox radiation impinging on the shield
tubes. You can her provide an estimate of this radiation load.
[Input item 171.1]

See also
Direct Radiation to Shield tubes
 FiredHeater Radiation Fraction absorbed by
First Row

The shield tubes are the first rows of convection bank tubes encountered by
the flue gases after leaving the firebox. Direct or indirect radiation from the
firebox gives an additional heat load on these tubes. You can specify the
fraction of this radiation absorbed by each of the first three rows of tubes, if
you wish to override the default values. The second row of tubes is partly
shielded by the first row, so will see less radiation, and the third row will see
less still.
[Input item 171.2]

See also
Direct Radiation to Shield tubes
 FiredHeater Radiation Fraction absorbed by
Second Row

The shield tubes are the first rows of convection bank tubes encountered by
the flue gases after leaving the firebox. Direct or indirect radiation from the
firebox gives an additional heat load on these tubes. You can specify the
fraction of this radiation absorbed by each of the first three rows of tubes, if
you wish to override the default values. The second row of tubes is partly
shielded by the first row, so will see less radiation, and the third row will see
less still.
[Input item 171.3]

See also
Direct Radiation to Shield tubes
 FiredHeater Radiation Fraction absorbed by
Third Row

The shield tubes are the first rows of convection bank tubes encountered by
the flue gases after leaving the firebox. Direct or indirect radiation from the
firebox gives an additional heat load on these tubes. You can specify the
fraction of this radiation absorbed by each of the first three rows of tubes, if
you wish to override the default values. The second row of tubes is partly
shielded by the first row, so will see less radiation, and the third row will see
less still.
[Input item 171.4]

See also
Direct Radiation to Shield tubes
 FiredHeater Include Radiation from Flue Gas

For each convection bank, you can select whether or not radiation heat
transfer should be included alongside convective heat transfer. This refers to
radiation from gas close to the tubes, and can apply in every convection bank.
It should not be confused with radiation to shield tubes, which applies only to
the first few tube rows adjacent to the firebox and relates to radiation from
the firebox.
[Input item 189.6]
 FiredHeater Gas-side Heat Transfer Coefficient

The gas-side heat transfer coefficient is normally calculated for every tube
row in every bank, based on flue gas properties and bank geometry. You can,
however, overwrite the calculated value in any bank, if you wish, by providing
input for this item.
[Input item 189.3]
 FiredHeater Fin or Stud Thermal Conductivity

The tube wall thermal conductivity in each convection bank is normally based
on internally stored values for the tube material. If, however, you want to use
a different value, you can identify the tube material as “user specified” and
supply a value for its thermal conductivity here.
[Input item 187.1]
 FiredHeater Heat Loss through Bank Duct Wall

You can specify here the heat loss from the flue gas through the walls of the
duct around a convection bank. This loss is additional to the heat transferred
from the hot gas to the process fluid.
This loss can be important for draught calculation, in determining the flue gas
temperature entering the stack. There is not yet any facility in the program to
allow for tramp air entering the flue gases, but specifying a heat loss can
model something similar, but not identical.
[Input item 185.5]
 FiredHeater: Highfin Heat Transfer Calculation
Method
The program provides a choice of method for calculating heat transfer over
bundles of high-finned tubes in convection banks.
The PFR 1976 method is an open-literature correlation which has been used
in previous releases of FiredHeater and FIHR.
The HTFS3A method has been developed from an HTFS research program
spanning a number of years, and it addresses both heat recovery and air-
cooled heat exchanger tube geometries. It applies to bundles of plain helical
fins (Fin types: Integral; G; L; Bi-metallic; Extruded; Shoulder-grooved) in
staggered and in-line arrangements. It is documented in Handbook Sheets
AM2 and AM4.
The ESCOA, or Weierman, method is a widely used open-literature
correlation.
 FiredHeater Temperature Drop in Stack

You can specify here a temperature drop in the stack, due to losses through
the stack wall. The resulting increase in mean density in the stack will reduce
the draught.
[Input item 197.6]
 FiredHeater Draw-off Fraction (Air-Preheater)

You can specify here a that fraction of the flue gases are drawn off prior to
the stack, then cooled, for example by being used to preheat combustion air,
and then returned to the stack. Specify a fraction of 1.0 if all the flue gas flow
is used for this purpose.
There is no internal link in the calculation between the heat loss of the
drawn-off gases and the inlet temperature of the burner air (oxidant inlet
temperature). You can however specify all the relevant flows and temperature
changes in the input, and then look at the Air Preheater section of the output,
to see how the heat loads and temperatures match.
[Input item 199.1]
 FiredHeater Temperature Drop of Draw-off Gas

Enter the temperature change of the any flue gas which is drawn-off from the
flue duct, cooled, and then returned to the base of the stack. This
temperature drop could arise because the flue gases are being used to
preheat combustion air.
Calculated values of the flue gas temperature in the flue duct, both before
and after this temperature drop, are displayed in the Output.
If the temperature after this temperature drop is below the (acid) dew point
of the flue gases, it is likely that your specified value of this temperature drop
is larger than would be used in practice.
[Input item 198.3]
 FiredHeater Temperature Drop of Remaining
Gas

Enter the temperature change of the gases that remain in the flue gas after
part of that gas has been drawn off, for example to an heat combustion air in
a pre-heater.
[Input item 198.3]
 FiredHeater Pressure Change of Drawn-off Gas

Enter the overall change in pressure of any flue gas that is drawn-off, for
example to go through an air preheater, before it is returned to the base of
the stack Any gas remaining in the flue duct will be subject to the same
pressure change, because of a requirement for a pressure balance of the flows
in parallel.
Note that this is a pressure change: losses are negative and gains positive.
Bends, changes in cross section, damper in the flue duct etc will cause
pressure losses. A fan would cause a pressure rise, which must be added
algebraically to any losses.
This parameter need only be specified if you have specified a flue system with
both stack and flue duct and require a draught calculation.
[Input item 198.2]
 FiredHeater: Preheater Inlet Air Temperature
Enter the combustion air temperature at the inlet to preheater. If
Calculate/set preheater flue gas temperature drop is Calculate gas DT, then
it is assumed that heating in the preheater is achieved by contact with flue
gases drawn from the base of the stack and that the temperature decrease of
the drawn-off flue gases is calculated by an energy balance. Other types of
preheater (steam heaters, run around coils) must be handled separately.
 FiredHeater: Calculate/Set Preheater Flue Gas
Temperature Drop
If an air preheater is present, then this item gives the user the option of
either:
· Calculating the temperature drop of drawn flue gas entering the
preheater by a heat balance with the combustion air preheat requirements.
The combustion air preheat requirement is calculated from the difference
between the preheater inlet temperature and the air/oxidant temperature at
the burner. It is assumed that this heating duty is achieved exclusively by
direct contact with flue gases drawn off from the base of the stack. Other
types of preheater (run-around coil, separate steam heaters) must be handled
separately. Currently with this option, no allowance is made for heat loss from
the preheater or associated duct work. If the preheater duty is not possible
due to temperature cross, the flue gas temperature drop will be calculated,
but an appropriate warning message will be generated.
· Specifying the flue gas temperature drop. The draw-off gas is drawn off
and re-introduced at the base of the stack. In this case it is up to the user to
make sure the heat load of the preheated air and drawn-off flue gases are
balanced.
 FiredHeater Number of Gas Zones

In the long furnace model of firebox radiation, the firebox is divided vertically
into a number of equal height zones, in each of which a full radiation
calculation is performed, for radiation between the hot gas and the various
zone surfaces. You can enter here the number of such gas zones into which
the firebox should be divided for calculation purposes.
If you are using the well-stirred model, there is a single radiating zone, and
this input item is not required.
The maximum number of zones is 10. Using fewer zones is often sensible,
unless the firebox is particularly tall and narrow. Using too many zones can
distort the thermal contribution of the zones adjacent to the floor and roof. A
default number of zones is calculated, based on the ratio of firebox height to
the width (or diameter) of the region within which radiation calculations are
performed.
The exact location of tubes within the firebox is sometimes adjusted slightly
for calculation purposes to match the specified number of zones. There is no
effect with vertical tubes which span from top to bottom of the firebox.
Vertical tubes which occupy only part of the firebox height, however, may be
effectively changed in length so that their height covers an exact number of
zones. It may be possible to adjust the number of zones to minimize the
effect of such distortion.
Horizontal tubes with multiple parallel paths, each with multiple tubes in
series, are modeled as if the paths were interleaved. This means that instead
of the various paths being at different levels in the firebox, it is assumed that
each path spans nearly the entire height region where tubes are present. For
example the first tubes in all the paths could be together at the bottom of the
firebox, with the second tube in all the paths being together a bit higher up,
and so on until the final tubes in all the paths are together at the top of the
firebox. This relocation of the paths can affect the appropriate number of
zones.
The program will sometimes determine that the initially specified number of
zones is not suitable, and revise it, issuing a warning message.
[Input item 130.1]
 FiredHeater Specify Heat Load Fractions in
Zones

When using a long furnace model for the firebox you must specify how the
heat release pattern in the firebox is to be determined. The options are;
Yes – User specified
With this option you specify what fraction of the combustion heat release
occurs in each of the zones. Zone one is always the one containing the
burner, whether there is top or bottom firing. Heat release fractions will
generally be zero in the higher numbered zones.
No – heat release calculated
If you do not know the heat release pattern, the program can calculate one
for you, using a flame model which has an exponential form and uses the
following two parameters,
1) the flame length
2) the fractional distance along flame length, at which the heat release has its
maximum value.
You can either input these parameters, or rely on default values set within
the model
If you have access to the HTFS Research Network, the flame model for heat
release is described in HTFS Handbook Sheet RM21.
The model used to calculate the heat release pattern does not explicitly allow
for the effect of burner-burner interactions and confinement on the flame
combustion characteristics. It is sometimes useful to regard the heat release
pattern, or the two flame parameters, as things you can adjust in order to
match heater performance achieved in practice.
[Input item 155.1]
 FiredHeater Flame Length

The flame length is used to determine the heat release pattern within the
firebox. You can either specify a value, or leave it blank, to let the program
determine a typical value for the fuel and burners specified. The flame length
is also use to calculate firebox pressure losses in the vicinity of the flame.
If you have access to the HTFS Research Network, more information on heat
release patterns is given in HTFS Handbook Sheet RM21, and on flame
pressure losses in HTFS Handbook Sheet RP9. Information on flame lengths is
given in HTFS Handbook Sheet RD3. Modern low NOx burners can however
sometimes have flame lengths rather different from those of traditional
burner types on which the HTFS default are based.
If you have a flame length from the burner manufacturer, or if you know it
from measurement or observations on the firebox itself, then input that
value.
Flame length can depend on the following factors:
1) Burner to furnace area expansion
2) Physical or aerodynamic blockage (swirl if applied)
3) Fuel injection mode (axial, radial, peripheral or any combination of these)
4) Fuel air ratio (air and fuel staging).
If you are using the program model for flame length, you should check that
you have set appropriate values for the Firebox input items:
1) The type of burner
2) The type of fuel (liquid or gas).
[Input item 155.2]
 FiredHeater Fraction along Flame of Heat
Release Maximum

If the program is calculating the heat release pattern, you must specify the
parameter ZFLM for use in the heat release model. This is the distance, as a
fraction of the flame length, at which the heat released has its maximum
value.
Gaseous fuels burn immediately and ZFLM typically has a value of 0. This is
the default for a gaseous fuel.
For liquid fuels the droplets have to be heated before they start devolatilising
and releasing combustible gases and ZFLM will have a non zero value, up to
1.0, to allow for this. The default if a liquid fuel has been specified is 0.3333
[Input item 155.6]
 FiredHeater Gas or Liquid Fuel

If you are allowing the program to calculate the flame length you should
specify the type of fuel you are burning, either gaseous or liquid.
Remember also to specify the type of burner you are using.
[Input item 155.5. 1 = gaseous, 2 = liquid]
 FiredHeater Heat Release Fraction in Zone

If you have elected to specify the heat release fraction directly, rather than
have it determined from a flame calculation, specify here the fraction of the
combustion heat release in each of the calculation (gas) zones – the equal
length zones spanning the firebox height.
Zone 1 is the zone containing the burner, for both top and bottom firing. The
heat release is likely to be concentrated in the lower number zones. If the
fractions you specify do not sum to unity, the program will normalize them.
This input is only used with the long furnace model. This model tends to
underestimate the radiation heat transfer from hot gas at the bottom of the
firebox to gas and surfaces higher up. You can compensate for this by slightly
overestimating the heat release fractions in zones further from the burner.
[Input items 156.1-10]
 FiredHeater Pressure Drop Multiplier
You can enter a multiplication factor which is applied to the calculated stream
frictional pressure drop, if you have reason to believe that the losses
calculated by HTFS methods is too high or too low for your particular system.
[Input item 207.5]
 FiredHeater Tube-Tube Loss in Firebox
(Velocity Heads)

Stream tube-tube pressure losses can be specified, as a number of velocity

heads, for the firebox, and for each convection bank. For convection banks,
this parameter applies to stream tube-tube pressure losses both within a tube
row, and between rows.
One velocity head is half the mass flux squared, divided by the stream
density. When the tube diameter, and hence mass flux changes, the mass flux
based on the smaller diameter is used.
Normally forged "U" bends will be used to inter-connect tubes often with
bends of 2D or 3D radii. In some heaters special plug headers will be used if it
is necessary to provide access for cleaning and de-coring.
For help on finding this loss coefficient for a particular geometry, you can look
in tables that give coefficients for different types of pipe fittings and sizes and
select a value that is most appropriate to your system. API 560 contains a
pipe fittings pressure loss coefficient table.
If you have access to the HTFS Research Network background information and
a method for calculating loss coefficients in circular arc bends is in Handbook
sheet FM2
[Input item 148.4 for fireboxes and input item 190.4 for convection tube
banks]
 FiredHeater Stream Tube-Tube Loss (Velocity
Heads)

Enter the pressure head loss coefficient which applies for the process fluid
flow connections from this tube bank to the next tube bank, or if appropriate,
to the firebox.
The stream pressure drop after the bank is calculated by multiplying the
velocity heads at exit (half mass flux squared over density) by the K value.
The mass flux in the pipework is assumed to be the same as in the tubes in
the bank, and the bank exit stream density is used.
Pressure losses quoted as equivalent lengths (Le/D) may be equated to losses
quotes as velocity heads (K) by the expression K = f(Le/D) (where f = friction
factor). The Chemical Engineers Handbook (Perry) recommends:
Liquids Le/D = 45 K
Gases Le/D = 55 K

[Input item 190.4]

 FiredHeater Stream Loss after Bank (velocity
heads)

Enter the pressure head loss coefficient which applies for the process fluid
flow connections from this tube bank to the next tube bank, or if appropriate,
to the firebox.
The stream pressure drop after the bank is calculated by multiplying the
velocity heads at exit (half mass flux squared over density) by the K value.
The mass flux in the pipework is assumed to be the same as in the tubes in
the bank, and the bank exit stream density is used.
Pressure losses quoted as equivalent lengths (Le/D) may be equated to losses
quotes as velocity heads (K) by the expression K = f(Le/D) (where f = friction
factor). The Chemical Engineers Handbook (Perry) recommends:
Liquids Le/D = 45 K
Gases Le/D = 55 K

[Input item 190.6]

 FiredHeater Pressure Change in Inlet Duct to
Firebox

Enter the overall pressure change in the inlet ducting to the firebox. This
should cover from the air intake to the heater to the point of entry to the
burner It should also include allowance for any dampers, fans and expansions
or contractions in the ducting.
This is a pressure change. Enter a pressure loss as a negative number and
enter a pressure gain as a positive number.
A duct system may include; a number of bends, changes in cross section,
surface air pre-heaters, dampers, an induced draught fan etc. In setting the
overall change in pressure in this ducting you must include an allowance for
the algebraic sum of changes (for example a fan will provide a positive
pressure change, a damper will provide a negative pressure change).
If you have access to the HTFS Research Network, background information
can be found in HTFS Handbook Sheet RM20.
This parameter need only be specified if you require a draught calculation
(Draught Calculation) that includes the pressure change over the inlet
ducting.
[Input item 116.1]
 FiredHeater Pressure Change across Burner

Enter the air-side pressure change across the burner. A figure will normally
be supplied by the burner manufacturer.
This is a pressure change. Enter a pressure loss as a negative number and
enter a pressure gain as a positive number.
This parameter need only be specified if you require a draught calculation.
[Input item 116.2]
 FiredHeater Pressure Change through Firebox
Arch

If you are carrying out a draught calculation, you can set the pressure change
that occurs as the combustion gases flow through the firebox arch. Specify a
negative pressure change if there is a pressure drop.
If omitted the program will calculate the pressure change using the various
cross sectional areas associated with the exiting the firebox.
This item is only needed if there is a firebox and a draught calculation is being
carried out.
[Input item 123.4 for cylindrical fireboxes and 133.4 for cabin fireboxes]
 FiredHeater Pressure Loss Coefficient for
Damper in Stack

If there is a damper in the stack, enter the loss coefficient (number of velocity
heads), associated with the pressure loss across a partially closed damper.
One velocity head is half the mass flux squared divided by the flue gas
density. The mass flux is based on the stack diameter at the point at which
the damper is located.
As an alternative to specifying this loss coefficient item, damper loss can be
expressed as a pressure difference, by incorporating it within the pressure
change associated with extras in the stack.
[Input item 198.2]
 FiredHeater Pressure Change for Extras in
Stack

Enter the extra pressure change allowed for any additional items that are
present in your stack.
Remember that since this is a pressure change, pressure losses must be
entered as a negative value and pressure gains as a positive value.
It is assumed that these items are located after the damper and transition
region, if present.
This parameter need only be specified if you require a draught calculation
(draught calculation).
[Input item 197.5]
 FiredHeater Flue Duct Velocity Head Loss

If you are carrying out a draught calculation, you can specify the number of
velocity heads lost in the flue duct, for gas flow between the end of the last
tube bank and the stack.
One velocity head is half the mass flux squared divided by the gas density.
This item is only needed if you are performing draught calculations.
If there is any draw-off of flue gas to an air pre-heater, this loss is assumed to
occur before the draw-off. The remaining loss in the flue duct is then the
same as the loss in the pre-heater through which part of the flow is diverted.
[Input item 194.3]
 FiredHeater Number of Iterations

You can select a maximum number of iterations for the main fired heater
calculation. If this number is exceeded, results are in most cases still
produced, but a warning may be issued that they should be treated with
caution.
Usually cases will converge in many fewer iterations than the default limit.
Occasionally increasing the number of iterations may make a case converge.
Often it may be appropriate to reduce the relaxation factor as well as increase
the number of iterations. Alternatively if a case does not converge, you can
use this parameter to explore the extent of variation, and hence uncertainty,
in the results.
[Input item 013.1]
 FiredHeater Relaxation Factor

The iterative calculation for a parameter such as an outlet enthalpy, involves

setting a new value of the parameter which is a weighted mean of the current
value and a predicted value. The relaxation parameter is the weighting given
to the new value. A value of unity would mean that the parameter is simply
reset to the predicted value every iteration. Such large relaxation parameters
run the risk of introducing computational instability. Lower values give more
stable calculations, but may require more iterations.
If you have a case which does not converge, you can try reducing the
relaxation parameter below its default value, to achieve convergence.
[Input item 013.2]
 FiredHeater Convergence Criterion
(Temperature)

You have separate control over the convergence limits which need to be
achieved, on both temperature and pressure, before an iteration is deemed to
have converged. Both the limits are relatively strict, and must be achieved on
a range of temperature and pressure parameters. If you get a message saying
that one has not converged, you may consider relaxing (increasing) the
convergence criterion slightly. Sometimes a relaxed convergence criterion
may make an unstable calculation stable.
[Input items 013.3-4 = temperature, pressure criteria]
 FiredHeater Convergence Criterion (Pressure)

You have separate control over the convergence limits which need to be
achieved, on both temperature and pressure, before an iteration is deemed to
have converged. Both the limits are relatively strict, and must be achieved on
a range of temperature and pressure parameters. If you get a message saying
that one has not converged, you may consider relaxing (increasing) the
convergence criterion slightly. Sometimes a relaxed convergence criterion
may make an unstable calculation stable.
[Input items 013.3-4 = temperature, pressure criteria]
 FiredHeater Warnings and Messages

Error messages, warnings and other messages may be generated when the
program is run various categories of message are displayed on separate tabs,
with a final tab displaying all the messages together.
Errors are fatal, in that they occur when something prevents the program
from running, or from generating results Input errors occur when required
input values are omitted, or when unacceptable input is specified Results
errors occur when the program fails to find an acceptable solution, for
example if the calculated pressure change exceeds the inlet pressure If errors
occur, they are always shown separately on the first tab.
Warnings are issued when the program encounters unusual values of certain
parameters, either input or calculated the calculation continues.
There are three categories of warning, which appear on separate tabs:
Input warnings are generated either by individual input items – for example
being out of range - or by combinations of input items.
Results warning relate to calculated results, and can point to uncertainties or
assumptions made during the calculations.
Operation warnings are produced when the calculated results indicate that
some aspect of the heater operating conditions may be undesirable.
Other messages or notes are produced for information purposes only, and do
not necessarily indicate a problem.
If you get an Error, you will have to change your input to get the program to
run Remember to look at warnings as well, as this may provide a clue as to
what the problem is.
With Warnings, you must exercise judgment about whether the results are
acceptable, or whether the program needs to be re-run with revised input.
The warning messages contain numerical values as well as text to help you
identify the cause of the problem.
As well as being generated when the program is run, Messages and Warnings
may also occur when a file type other than EDR is imported After any import,
whether or not messages are generated, you should review in input carefully,
both imported values and defaults, to check that they are all acceptable.
 FiredHeater Recap of Designs

Recap of Designs gives you a list of key results generated for each run. It is a
very useful facility for comparing the results of a succession of runs.
An initial list of the parameters displayed is built into the Recap of Designs
feature. There is however a facility to customize this list and select various
other parameters to display. You can also delete columns for certain runs, so
that you can manage the amount of data shown
When you save case, the Recap of Designs parameters from your most recent
run are saved, so when you open it again, the first column of Recap of designs
shows these saved values.
 FiredHeater FiredHeater Summary

The FiredHeater Summary shows two tables of key results generated by a

run:
The first table gives overall parameters relating to heater efficiencies, fuel
usage and hot gas conditions.
The second table gives overall results for the firebox and for each convection
bank, with inlet and outlet conditions for both process stream and hot gas in
each, together with information on heat fluxes and peak tube wall
temperatures.
 FiredHeater Stream Overview

The stream overview gives the process conditions and properties for each
stream at its overall inlet and outlet to the heater system.
Process conditions include the temperature, pressure quality (vapor mass
fraction) and specific enthalpy at inlet and outlet, together with the flow and
heat load.
Properties include the density, specific heat viscosity and thermal conductivity
of liquid and/or vapor phases, together with surface tension and phase
molecular weights and Prandtl numbers.
 FiredHeater Bank Performance

The Bank performance gives information for process streams and flue gases in
each convection bank
Stream process conditions include the temperature, pressure quality (vapor
mass fraction) and specific enthalpy at inlet and outlet, together with the
pressure drop, flowrate and heat load. Flue gas inlet and outlet temperatures
are included alongside the stream temperatures, to provide information on
driving temperature differences.
Flue gas information includes inlet and outlet temperatures and pressures,
pressure drop (for draught calculations) and heat loss to process stream and
to the duct wall The gas mass velocity (mass flux) shown is based on the
minimum flow area between tubes, including allowance for any finning.
Overall gas-side heat transfer coefficients and fouling resistance are shown,
together with the associated fin efficiency Gas density, specific enthalpy,
Reynolds numbers and Prandtl numbers are shown at inlet and outlet.
A third tab gives information on heat fluxes and temperatures in each
convection bank The mean and maximum heat flux are given, based on both
bare tube area and finned area Maximum values are given of the tube
temperature, on both the inside and outside wall of the tube, and on the
inside of any internal fouling layer in contact with the process fluid A separate
table gives the overall convective and radiative components to the convection
banks The radiative component is the load on the shield tubes, the convective
load is from the hot gas passing over the tubes.
 FiredHeater Firebox Performance

The Firebox Performance results consist of five tabbed pages The first gives
overall information on the combustion process, while the second details the
heat balance within the firebox, showing the heat transferred to the process
fluid, the heat lost to the wall and that lost via the flue gases The heat arising
from combustion is shown, together with smaller contributions to the heat
balance such as fuel and oxidant preheats, and atomizing steam if used. The
radiative and convective components of heat transfer within the firebox are
then identified.
The last three tabs then concentrate on heat transfer to the process stream.
The Process Stream tab shows stream conditions at inlet and outlet to the
firebox, including temperature, pressure, enthalpy, quality (vapor mass
fraction) and liquid and vapor flowrates. If there is steam injection,
temperatures and pressures before and after the injection point are also
shown.
The Tube Groups tab gives information on process conditions at inlet and
outlet to each tube group The Fluxes + Temperatures tab gives information,
both for the overall firebox and for each tube group, on peak heat fluxes and
maximum tube inside and outside temperatures. Both for the circumferential
mean, and the circumferential maximum temperature are shown The initial
radiation calculation assumes a tube temperature which varies along the tube
length, but which at any point is uniform around the circumference This is the
circumferential mean, for which the maximum value along the tube is shown.
An API correction is then applied, which estimates the circumferential
variation of heat flux around the tube circumference at any point From this
the “circumferential max” temperatures can be calculated The temperatures
values should be treated with some caution, as there are physical features
such as circumferential conduction around the tube wall, and higher local heat
transfer coefficients at higher temperatures which are not accounted for.
If there is a single tube group, then the individual tube group information
duplicates information for the process stream and firebox overall If you need
more detailed information on certain tubes, it is always possible to rerun,
having artificially set more than one tube group These would have the same
tube characteristics, but with the number of tubes in series in each group
adjusted to give the correct total number in series.
 FiredHeater Flue Gas Overview

The Composition tab gives the flue gas composition in both a mass and molar
terms, and on both a wet and dry basis. If you have specified a fuel containing
sulfur, a figure is also given for ppm of sulfur dioxide, referred to a standard
oxidant flow giving 3% oxygen in the flue gas
An Air Preheater tab collects together information potentially relevant to an
air preheater This includes the flowrate, temperatures and pre-heat heat load
of the combustion air, and the flowrate, temperatures and heat loss of any
flue gas fraction which you specified in the program input, under Program
Options | Thermal Analysis | Air Preheat.
The program does not at present explicitly define or model an air preheater,
so it does not explicitly link the flue gas heat loss to the air preheat load, and
the two will normally be different If there is an air heater in which the flue
gases heat the combustion air, then you can adjust oxidant inlet temperature,
and/or flue gas temperature drop or draw-off fraction in order to achieve a
balance. Additional output information on LMTD and UA value in the
preheater can then be useful LMTD is the log-mean temperature difference,
based on a pure counterflow exchanger, and UA is the product of the U-value
(overall heat transfer coefficient, assumed constant) and preheat exchanger
area.
The final Flue Gas tab is Stack, giving information on flow area, mass
velocity, and pressure and temperature changes within the Stack, if you have
specified a draught calculation, and given details of the Stack in the program
input.
 FiredHeater Fuel and Oxidant

The Fuel and Oxidant results are shown on three tabbed pages, one relating
to Combustion overall, the others to Fuels and Oxidants Much of this output
simply reflects what has been supplied in the input, though in a more
complete form. For example fuel and oxidant compositions are given on both
a mass and a molar basis.
These outputs are particularly useful if you have specified more than one fuel
or oxidant, since composition information on the corresponding fuel mixture
or oxidant mixture is also provided here.
 FiredHeater Solution Overview

The Solution Overview tab gives a small amount of additional information on

the calculation performed, including the number of iterations performed, and
the solution errors in both the firebox and convection section.
 FiredHeater Stream Details

The Stream details table gives information on stream, wall and gas
temperatures and heat fluxes at points along the flow path of each process
stream.
The points are numbered in order of flow, and a corresponding distance along
the flow path is given for each point A tube bank number is given in
convection banks, and a tube group number in the firebox For convection
banks the row number is given for each tube Rows are numbered from the
flue gas inlet end of the bank The tube number in the path, within each
convection bank, or each firebox tube group is also given.
The number of points given will depend on the geometry details In general
one point is given in the middle of each tube in the path, together with extra
points at the beginning(inlet) of the first tube and end(outlet) of the last tube
in each convection bank or tube group. Stream process conditions are given
at these extra inlet and outlet points, but other heat transfer parameters are
only given at the mid-tube points.
 FiredHeater Stream Properties

The Stream Properties output, for each process stream, gives the major
properties of each phase at a series of points between inlet and outlet.
Properties include density, specific heat, viscosity and thermal conductivity,
together with quality (vapor mass fraction).
The points given are equally spaced in enthalpy and equally spaced in
pressure, between inlet and outlet in each case This means that the points do
not exactly follow the path of the stream through the heater, since pressure
changes and enthalpy changes do not usually go hand in hand Since
dependence on pressure is small form most property parameters, this
distinction between the actual enthalpy pressure path, and the simple
proportional path is usually of limited importance.
 FiredHeater Zone Details

Zone details results are created when a Long Furnace calculation model is
specified for the firebox Information is provided, for each calculation zone, on
the fraction of the combustion heat released in that zone, and for the
temperature and radiation properties for each surface of that calculation
zone.
Zones are numbered beginning at the burner location (usually the bottom) in
the firebox, and are of equal height Only the first zone will have a bottom
surface, only the top zone a top surface All zones will have side surfaces In a
cabin firebox, there will be front, back, left and right had surfaces, with the
firebox tubes on the right and/or left surfaces In a cylindrical firebox, there is
a single surface zone.
 FiredHeater: Draught Details
This form reports the draught losses for the major items in the heater if
Draught calculation has been set to Yes (Application options form). The
reported values can be used to determine if the current draught configuration
in the heater is likely to be acceptable. In practice, the actual draught at a
location in the heater will be affected by the settings of dampers and fans and
so the values give are intended to be indicative.
If the sum of all draught losses is greater than zero, then this indicates that
some additional draught generation is required either through the use of fans
or a taller stack.
If draught losses are less than zero, then the excess needs to be controlled by
closing dampers or burner air registers. Normal operating practice would be to
aim for a draught of –0.1 in of H20 (-25 Pa) at the bridge-wall (exit of the
firebox).
Draught is defined as the flue gas pressure inside the heater minus the
atmospheric pressure outside the heater at the same elevation. A negative
value indicates a slightly lower pressure inside the heater. The draught losses
for each individual item are further divided into: friction losses, acceleration
losses, and buoyancy losses.
Friction losses are either fluid-on-wall (e.g. in a convection bank) or fluid-on-
fluid (e.g. at the exit of the burners) friction resulting in the irreversible
generation of heat.
Acceleration losses are the (reversible) pressure losses needed to accelerate
the flue gas either due to a change in cross-sectional area or gas density
changes.
Buoyancy losses are due to elevation differences combined with density
differences. A typical example of this is the stack where the draught gain
through buoyancy is given by ((ramb – rgas))gH.
In most cases, draught losses are calculated using simple fluid flow
calculations which are described in HTFS Research Network report RM20.
However, some items currently require direct input by the user. These are:
losses at the burners; combustion air-side of the preheater and inlet ducting;
and also the flue gas-side of the preheater (all set in Input | Program Options
| Pressure drop).
 FiredHeater: Flue Gas Properties
Flue Gas Properties lists the important properties (Specific Enthalpy,
Density, Specific heat, Viscosity and Thermal Conductivity) of the flue gas at
various points between the firebox and the outlet to the heater.
Zero datum for specific enthalpy is 25 degC, 1 Bar (gas phase).
 FiredHeater Overview of Firebox (general)

FiredHeater can deal with cylindrical fireboxes with horizontal or vertical

tubes, and with cabin fireboxes, which can either be centrally fired with tubes
along two opposite walls, or can have a single or double row of central tubes,
with firing on each side. It can also model multi-cell cabins and roof tubes in a
simple cabin. Tubes in a cabin firebox can be either horizontal or vertical.
FiredHeater can model twin fireboxes exhausting into a single duct. It cannot
yet explicitly model cabins with tubes on all four walls, or with both wall and
central tubes.
The term "cabin" is used in Fired Heater to mean a firebox that can be
modeled as a 3-dimensional rectangular "box". It thus applies strictly to box
heaters. FiredHeater does not explicitly model cabins with sloping roofs. Such
cabins must be defined as an equivalent simple box.
The firebox tubes are assumed to carry a single process fluid stream that
passes through one or more parallel paths. Each path consists of a sequence
of tubes connected in series. The U-bends connecting the tubes in a path can
be specified as being inside or outside the firebox. The tubes within a path can
be identical, or can vary. For example, in vaporizing duties larger diameter
horizontal tubes may be used for the tubes where the stream is expected to
be fully vaporized.
To simplify the specification of the tubes in a path, the concept of “Tube
Groups” is used. A tube group is a set of identically-sized tubes in series. Each
path consists of one or more tube groups in series. One tube group is thus
specified for each size tube in the firebox. Only one tube group is needed if
the size and spacing is the same for all the firebox tubes.
The tube sequences forming the parallel paths can either be interleaved
(interspersed), or they may be separate. Separated paths, implies that each
tube in a path is adjacent to the next tube in that path, rather than a tube in
a different path. For horizontal tubes the case of separate paths can only at
present be handled using a well-stirred furnace model. For horizontal tubes
with the long furnace model, the tubes are treated as though they were
interleaved. All parallel paths are thus assumed to be subject to the same
heat load profile.
Firebox calculations are performed by dividing the firebox height into a
number (up to 10) of equal length zones, in which radiation heat transfer is
evaluated between the hot gas and the cabin walls (and floor and roof). The
simplest model, with a single zone, referred to as the well-stirred model, is
adequate in many cases.
When you use multiple zones (the long furnace model) you can either specify
the number of zones yourself, or use a default supplied by the program. The
program will identify which firebox tubes are in which zone or zones,
distorting the actual geometry slightly to achieve this. A warning is issued if
this has significant implications, and you can explore using a different number
of zones.
The burners can be located either in the firebox floor or roof.
If you have a firebox with wall burners, this is fine in the well-stirred model,
for which the exact location of the burners is unimportant. For the long
furnace model you should model the firebox as if it had floor burners and set
the firebox heat release pattern so that it distributes the heat release to
match the loading of the wall burners.
 FiredHeater Overview of locating Vertical Tubes
in Firebox

The axial locations of vertical tubes are defined by specifying the firebox tube
(straight line) length, and the height of the bottom of this length above the
firebox floor. Alternatively, if you specify the number of zones in the firebox,
you can define the first and last zone containing the tube (zones are
numbered from the bottom). Specifying the length and height are preferable
as this can allow for tubes that begin or end part-way through a zone.
The process stream in a firebox with vertical tubes is assumed to flow through
a number of identical parallel paths, each comprising a sequence of tubes with
alternate up-flow and down-flow. The spacing of tubes in a path (centre to
centre), which is the diameter of the U-bend connecting the tubes, can be
defined. The various tubes within the path can be different. For example,
there might be six tubes in a path, the first two, nearest entry, having a
smaller diameter and spacing then the rest of the tubes in the path. In such a
case it would be necessary to specify tube one and tube three. Unspecified
tubes are assumed to be identical to the preceding tube.
Vertical tubes (unlike horizontal tubes) are numbered in the direction of
process fluid flow. You must specify whether the first tube is in up-flow or
down-flow and FiredHeater will work out the flow direction in the rest of the
tubes.
Vertical tubes may be arranged in up to 60 parallel paths and you must say
how many paths there are. (In the case of a cabin firebox containing wall
tubes you must say how many parallel paths per wall there are.) These paths
can be defined as being separate or interleaved. Separate means that groups
of adjacent tubes are connected into a path sequence and such sequences are
assumed to be equally spaced around the wall of a cylindrical firebox, or along
the length (depth) of a cabin firebox.
All parallel paths within a firebox are assumed to be identical in structure and
performance.
All the tubes in the firebox are assumed to be of the same material, and to be
the same distance from the wall. If the actual distance from the wall varies,
input some appropriate mean distance.
 FiredHeater Overview of locating Horizontal
Tubes in Firebox

The process stream in a firebox with horizontal tubes is assumed to flow

through a number of identical parallel paths, each comprising a sequence of
tubes with flow in alternate directions. The spacing of tubes in a path
sequence, which is the diameter of the U-bend connecting the tubes, can be
defined. The various tubes within a path sequence can be different. For
example, there might be six tubes in a path, the first two, nearest entry,
having a smaller diameter and spacing then the rest of the tubes in the path.
In such a case you would specify two tube groups, one with two tubes in
series, and a second with a different diameter and four in series
You can set the location of the lowest tube by inputting its height above the
bottom of the firebox (the burner plane). For top firing, you set the height
difference between the top tube and the burner plane. You should also set the
overall flow direction for the fluid in horizontal tubes as being either up or
down.
Horizontal tubes in different parallel paths indifferent parts of the firebox will
in practice experience somewhat different radiation loads. FiredHeater at
present models a representative path that is it assumes each parallel path is
identical. In the long furnace model, horizontal tube paths are treated as
though they are "interleaved", so that, rather than the normal practice of all
the tubes in series in each path being adjacent, for each tube, the
corresponding tubes in all paths are adjacent.
All the tubes in the firebox are at present assumed to be of the same
material, and to be the same distance from the wall. If the actual distance
from the wall varies input some appropriate mean distance.
 FiredHeater Overview of Firebox Zoning Model

A firebox is divided for calculation purposes into a number of ‘gas zones’ of

equal height. Within a zone the hot gases are assumed to be at a uniform
temperature, which FiredHeater evaluates. Radiation between the zones, and
the various walls, and each firebox tube in each zone is a key element of the
heat transfer calculation within the firebox.
If FiredHeater uses only 1 gas zone this is referred to as a well stirred model.
If more than 1 gas zone is used this is referred to as a long furnace model.
You can either specify the number of gas zones yourself (up to 10), or let
FiredHeater set it automatically based on the height of the firebox.
FiredHeater will automatically allocate tubes, or regions of tubes, to the gas
zones, based on geometric information you provide. Some level of
approximation is involved in doing this for horizontal tubes. Selecting the
number of zones so you have the much same number of horizontal tubes in
each zone reduced the extent of the approximation. You will need to specify
the number of zones if you wish to define the firebox heat release pattern, in
terms of the heat release in each zone. You do not need to specify the heat
release pattern if you use the well-stirred furnace model (uniform heat
release per unit length), or if you provide information about the burner and
flame length from which the heat release pattern can be estimated.
For vertical tubes, each tube passes through a range of zones, though there
may be zones at the top or bottom of the furnace without tubes and if you are
using a long furnace model FiredHeater will provide you with a performance
profile for each tube. If you are using a well stirred model you will be given
the mean performance of each tube.
For horizontal tubes, each tube will be in a single zone and, regardless of the
model being used for the firebox; FiredHeater will provide you with the mean
performance of each tube rather than a performance profile for each tube.
 FiredHeater Typical Duties

A typical, but not exhaustive, list of duties for which fired process heaters are
used includes;
Hot Oil Heaters
Refinery Charge Heaters
Reactor Charge Heaters
Fired Reboilers
Regeneration Heaters
Cracking Furnaces
Reforming Furnaces
 FiredHeater Cylindrical or Rectangular Firebox

Firebox process heaters up to 2-40 MW will usually be cylindrical, larger ones

rectangular
Above this size, the height of a cylindrical heater will have become such that
the upper part of the firebox is very remote from the flame, and will receive
relatively little radiation This is particularly true with natural draught burners
Rectangular heaters are generally more expensive and take up more ground
space for a given heat release.
 FiredHeater Gaseous Fuels

Gaseous fuels for process heaters vary from hydrogen through to butane, and
may also include low calorific value fuels containing carbon monoxide and
inert gases
 FiredHeater Radiative Heat Transfer
(Convection Section)

Although the heat transfer in the convection section is primarily by

convection, radiative transfer does occur and must be allowed for In
particular, radiation from the firebox will fall on the front rows of tubes if
these can "see" the firebox, and this will normally penetrate, at least to some
extent, as far as the third row. Radiation will also occur even when the tubes
cannot directly see the firebox, this being the radiation emitted by the volume
of hot flue gas directly in front of the tubes. If the temperature is sufficiently
high and the volume sufficiently large this will be significant. Thirdly,
radiation will occur within the tube bank and at the hot end of the bank will
make a significant contribution.

See also:
Shield Tubes
 FiredHeater Firebox (Principal Features)

The firebox may be rectangular or cylindrical in section and is lined with a

refractory material, which may be firebricks, refractory concrete or ceramic
fiber
Rectangular heaters are generally used for large duties and cylindrical ones
for small duties, the break point being somewhere in the region 20-40 MW
absorbed, and height to diameter ratios are typically between 2 and 3
The refractory lining of a process heater is usually between 100mm and
200mm thick.
 FiredHeater Burners (Principal Features)

Burners may be positioned in the firebox so as to fire vertically upwards

("upshot") or downwards ("downshot") or horizontally
Cylindrical heaters are invariably fired axially Upshot firing is by far the most
common, the vertical cylindrical upshot heater being probably the most widely
used type of heater in the process industries
In some types of heater, known as Radiant Wall Heaters, the burners are
arranged to fire on to the refractory surface, and it is then that surface,
rather than the flame itself, which radiates to the tubes
The number of burners may vary from one in a small cylindrical heater to up
to 100 or more in a large radiant wall heater.
Both forced draught and natural draught burners are used in process heaters
The natural draught type has the advantage of cheapness and simplicity and
was used most exclusively for many years Many are still being installed on
new heaters, but the drive for efficiency and better flame control to minimize
the emission of polluting species, particularly NOx, has led to the increasing
use of forced draught burners on both new installations and retrofits
In a natural draught burner, combustion air is drawn into the burner by the
draught created by the column of hot flue gas in the heater or by the motive
force of the fuel gas injected, or by a combination of these
In a forced draught burner, the air is blown in by a fan and more pressure
drop can be made available to promote better mixing.
 FiredHeater Radiant Tubes (Principal Features)

The radiant tubes may be located on the walls, roof and (more rarely) floor. It
is not normal practice to install tubes on the same walls as the burners The
tubes generally stand off from the wall by 0.5 to 1.5 tube diameters and are
set on a pitch of 2 to 3 diameters (tube diameters are between 50 and 150
mm) This arrangement permits radiative heat to be absorbed on the back face
of the tubes after reflection or absorption and re-emittance at the refractory
surface.
Tubes may also be suspended in the centre of a rectangular firebox to enable
them to be directly heated from both sides These are called central tubes and
give a more even heat flux distribution Large heaters may feature both wall
and centrally located tubes either with two or more lanes of burners, or
divided into a number of firing cells each with its own large burner Some,
notably in the Oil industry, are provided with two separate fireboxes sharing a
common convection bank, ducting and stack A wide variety of layouts is
possible, of which a selection is shown in the following article by Berman;
BERMAN, H.L(1978) ‘Fired heaters I - finding the basic design for your
application’, Chemical Engineering, June.
In a rectangular firebox the tubes may run vertically or horizontally while in a
cylindrical firebox they may be arranged axially or in the form of a helical coil
The straight horizontal or vertical tubes, except in the rare case where flow is
through all the tubes in parallel, are joined together by U-bends to form one
or more "hairpin" coils. These coils, through which the process fluid flows in
parallel, are often referred to as "passes" - a term which is, unfortunately,
confusing to those versed in shell and tube heat exchanger terminology The
term "parallel paths" is clearer and it is better to refer to a coil as, for
example, a "4-start coil" rather than a "4-pass coil" The U-bends are generally
inside the firebox.
An alternative arrangement, found in small cylindrical units of up to about 3
MW capacity, consists of a tight-wound helical oil, in which the turns actually
touch each other This ensures that only the front of the tubes sees radiant
heat from the flame The hot gases are forced to flow to the end of the firebox,
and may then be either exhausted from the top of the firebox or forced round
the end of the coil, and back down the space between the coil and the
refractory lining before being exhausted from the burner end of the heater In
this later arrangement, which facilitates the use of a recuperative air
preheater, the heat transfer on the pass down the outside of the coil is
primarily convective.
 FiredHeater Convection Section (Principal
Features)

The hot flue gases leave the firebox at a temperature between 900 K (600°C)
and 1400 K (1100°C). Heat may be recovered from these flue gases by
passing them across one or more banks of tubes located either directly above
or downstream from the firebox. In these tube banks the mechanism of heat
transfer is primarily by convection - hence the term convection section or
convection banks.
With a radiant section alone, thermal efficiencies of 60% at best can be
achieved and for high temperature duties this may fall to as low as 40%The
use of a convection bank of course requires a heat sink of sufficiently low
temperature In the simplest case, this will be the firebox process fluid itself If
the desired process fluid inlet temperature to the firebox is sufficiently low
(generally less than about 750 K (500°C)), then some of the fluid can be fully
or partially preheated in the convection section If the firebox inlet
temperature of the process fluid is too high, or further enhancement of
efficiency is required, then the convection section can be used for other duties
- such as raising steam, heating boiler feedwater or even another process
duty In this way, efficiencies in the region of 90% can be obtained.
The tubes in the convection bank are set normal to the gas flow - usually they
are horizontal and the gas flow is vertical They are generally set on
equilateral pitch, either square or triangular, of about 2 diameters, with lanes
for cleaning left every few rows. Square pitch tubes are easier to clean , but
triangular ones give better heat transfer Mostly, the convection bank is
located above the radiant section, but in some very large heaters with large
convection banks, a separate free-standing convection bank is fitted
downstream of the firebox.
FiredHeater can model convection sections in which the gas flow is vertical
and the tube are horizontal or those in which the gas flow is horizontal and
the tubes either vertical or horizontal. Combined convection sections that
have both vertical and horizontal gas flow can also be modeled For each bank
you can specify the combustion gas flow direction, the tube orientation, and
the overall process fluid flow relative to the combustion gas flow.
The convection section typically consists of a bank of plain tubes, called the
shield or shock tubes, and one or more banks of extended surface tubes.
Often the shield tubes are used to preheat the firebox process fluid and the
banks of extended surface tubes to raise steam in a waste heat boiler system.
See also:
Radiative Heat Transfer (Convection Section)
Gas Side Heat Transfer versus Pressure Drop (Convection Section)
Process Side Flow Arrangement (Convection Section)
Gas Side Fouling (Convection Section)
Low Exhaust Gas Temperature (Convection Section)
Regular Tube Banks
Irregular Tube Banks
 FiredHeater Shield Tubes (Principal Features)

The first two or three tube rows in the convection section, which are in
contact with the hottest gas and in most cases also receive radiation from the
firebox and form the first tube bank, usually consist of plain tubes to avoid
overheating. These tubes are often referred to as the Shock or Shield Tubes.
 FiredHeater Extended Surface Tube Banks
(Principal Features)

Most of the convection section tube banks use tubes with extended surfaces,
to enhance the gas-side heat transfer rate.
Annular fins are the most common form of extended surface, but cut or
serrated fins and studs are also used
The fins are thicker than those used on air coolers - typically 2 to 3 mm, and
more widely spaced The spacing depends partly on the degree of fouling
expected - spacing of up to 6 fins per inch (240 per meter) is used for clean
gas-fired duties, but this is reduced to as low as 2.5 per inch (100 per meter)
for fouling duties The height of the fins is between 12 and 30 mm They are
generally integral with or welded to the parent tube - other forms of
attachment are unreliable in such a harsh environment.
 FiredHeater Waste Heat Boilers (Principal
Features)

A part of the convection section may be used to raise steam, and in this case
is usually referred to as a Waste Heat Boiler This should not be confused with
the waste heat boilers which are often fitted on the process side exit
In addition to the raising of steam, the convection section can also be used to
preheat boiler feedwater in an Economizer and to superheat steam The
arrangement is similar to that for any other fluid in the convection section,
except that if the boiler is to operate under conditions of Natural Circulation
the tubes must be inclined to the horizontal If a Waste Heat Boiler forms the
major part of the convective surface, then it may be arranged so as to have
the tubes vertical and the gas flow horizontal
Waste Heater Boilers are further discussed in HTFS Handbook Sheets RP10
and BE7 (available via the HTFS Research Network)
 FiredHeater Air Preheaters (Principal Features)

Air preheating, although not widely employed on Process Heaters, is gaining

increased acceptance as higher and higher efficiencies are sought. However
this must be balanced with the fact that air preheating causes flame
temperatures to increase which then results in an increase of NOx emissions.
Air preheating may be achieved by using waste process heat or surplus steam
which arises on many process plants, by the use of hot exhaust gases (e.g.
from gas turbines) in place of air or by direct exchange between air and flue
gas.
If the preheating medium is steam or a hot process fluid, the normal practice
is to use tubes with extended surfaces, similar to those used in the convection
banks This type of preheater can also be used to effect indirect exchange
between flue gas and air using an intermediate fluid and a reheat coil in the
convection section. Such an arrangement avoids the complicated ducting
often associated with air/flue gas exchange.
Where air is exchanged directly with flue gas, a number of different types of
exchanger are available. These fall into two categories - regenerative, where
a heat sink is alternately heated in the flue gas and then cooled by giving up
its heat to the air stream, and recuperative where heat transfer between the
flue gas and air takes place directly across a surface.
The following varieties are found in Process Heater applications:
– Rotary Regenerative - a rotating drum or wheel, containing a
heat-retaining matrix through which gases may flow, is placed so that half
of each revolution is within the flue gas, picking up heat, and the other half
within the air giving up heat These are generally only found on large
heaters (over 50 MW).
– Fixed tubular - using tubes similar to those in the convection
bank.
– Fixed Integral-Channel - various proprietary designs in which
pressed steel or cast iron plates are assembled to provide a large number of
alternating channels for flue gas and air.
– Recuperative Burners - the exhaust air is drawn out through the
burner assembly preheating the air flowing into the burner Generally
restricted to smaller heaters with relatively high exhaust temperatures.
Air heater design is more fully discussed in HTFS Handbook Sheet RP10
(available via the HTFS Research Network)
 FiredHeater Fans, Stacks, Ducting and Dampers
(Principal Features)

Fans may be employed either to supply air to the burners (forced draught) or
to extract flue gases from the heaters (induced draught) or both (balanced
draught)
Process heater fireboxes are run at a pressure slightly below atmospheric.
This prevents hot gas leaking out, which could damage the structure of the
firebox and be hazardous to operators The difference between the
atmospheric pressure outside the heater and the pressure inside the heater is
referred to as draught, and is normally maintained at a minimum level of 1 to
2 mm of water gauge (0.1 to 0.2 mbar)
Too high a draught will increase the amount of air drawn into the firebox
through sight doors, instrument connections, tube seals etc This "tramp air"
reduces furnace efficiency as energy is absorbed in heating it to the final
exhaust gas temperature
The draught in the firebox, and the suction required to overcome the gas
pressure drop through the convection section is provided either by the
chimney effect of the stack, or by an Induced Draught Fan It is controlled by
means of a damper located in the ducting leading to the stack or fan In a
forced or balanced draught system, dampers or inlet guide vanes will also be
used to control the air rate through a forced draught fan, and to balance the
distribution of air to the various burners.
The stack discharges the flue gases to a safe location such that they cannot
endanger personnel or nearby equipment, and that local pollution
requirements are met In the absence of an induced draught fan it also
provides the necessary draught to overcome the pressure loss across the
convection bank, damper and ducting and provide adequate draught at the
top of the radiant section.
 FiredHeater Heater Configuration (Design
Considerations)

The designer must first decide on the type of heater to be used

Most process heater duties will involve a firebox (radiant section) and a
convection section However for small and intermittent duties, such as catalyst
regeneration, a simple radiant-only heater may well suffice - the low
efficiency being acceptable for use maybe only one or two days per month
Where a convection section is installed, the simplest configuration is to pass
the incoming process fluid through the convection bank(s) counter-currently
to the flue gas. This arrangement, which applies to the vast majority of
process heaters, will enable the stack gases to be cooled to within about 50 K
of the inlet process temperature Beyond this point, design becomes more
complicated with consideration being given to air preheat, steam raising and
other process duties
Increasingly, the optimization of stack gas heat recovery is being treated as
part of an integral energy study covering the entire process - not just the
process heater Where a number of process heaters are installed on a plant,
they may well be of simple and relatively inefficient design themselves, but
ducted into a common heat recovery system such as a large waste heat
boiler.
Where relatively low temperatures are required and the risk of overheating is
to be avoided, or a very even heat flux is required, such as in certain kinds of
reactor heating, a convective-only heater may be used. In this type of system
the burner fires into a combustion chamber which does not contain tubes and
exhausts into a recirculatory ducting system. In this way, the tubes see only
relatively cool gas, and high fluxes due to radiation on the front tubes are
avoided. A large flue gas recirculation, perhaps up to 20 times the primary
flue gas rate is generally incorporated Another feature is that some of the
recirculating gases may be put back into the burner, which would reduce
flame temperatures and so help reduce NOx formation.
 FiredHeater Efficiency (Design Considerations)

It is normal to express the efficiency of process heaters in terms of the Net or

Lower Calorific Value.
For a large modern heater the target efficiency, on the basis of the
percentage of heat input from the fuel lower calorific value absorbed by the
process fluids, should be in the region of 90%.
Higher net efficiencies will be obtainable for gas than for oil - partly because
gas burners can operate with a lower level of excess air, and partly because of
exhaust gas dew point considerations.
 FiredHeater Exhaust Gas Temperature (Design
Considerations)
On gas fired heaters, the dew point of the flue gas is around 330 K (57°C)
and the condensate is water made slightly acidic by dissolved CO2 and NOx.
With sulfur-laden fuels a more serious problem arises in that dilute sulfuric
acid is formed. The presence of this acid not only increases corrosion but
raises the dew point considerably, perhaps to as high as 415 K (142°C) when
burning 3.5% sulfur fuel oil.
It is important that not only must the stack gases exceed this dew point but
also all the metal surfaces in contact with them. In practice this gives a
minimum exit temperature of around 380 K (107°C) for gas firing, 450 K
(177°C) for high-sulfur fuel oil firing.
This topic is more fully discussed in the following HTFS Handbook Sheets,
available via the HTFS Research Network .
· RP14: NOx reduction techniques: a critical review
· RP15: SO2 reduction techniques: a critical review
· RP16: CO2 reduction techniques: a critical review
See also:
Low Exhaust Gas Temperature (Convection Section)
 FiredHeater Fuels (Design Considerations)

The choice of fuel will depend largely on local circumstances, and this often
dictates considerable flexibility.
Radiant wall heaters are nearly always fired on gas - this is because of the
small size of the individual burners, the need for precise flame shape control
and the deleterious effect of contaminants in oil fuels on the refractory.

See also:
Gaseous Fuels
Liquid Fuels
Solid fuels
 FiredHeater Burners (Design Considerations)

Natural Draught Burners

Forced Draught Burners
 FiredHeater Firebox (Design Considerations)

Cylindrical or Rectangular Firebox

Firebox Aspect Ratio
Flame and Firebox Height
Firebox Heat Losses
Firebox Heat Flux
Heat Input from Fuel
 FiredHeater Radiant Coil (Design
Considerations)

Firebox Heat Flux

Horizontal or Helical Tubes
Vertical Tubes
Process Side Fouling
 FiredHeater Convection Section (Design
Considerations)

Key factors to be considered in the design of the convection bank are pressure
drop and heat transfer rate requirements, which often conflict with each
other, and tube and fin/stud metal temperatures.

See also:
Radiative Heat Transfer
Gas Side Heat Transfer versus Gas Side Pressure Drop
Process Side Flow Arrangement
Gas Side Fouling
Low Exhaust Gas Temperature
Regular Tube Banks
Irregular Tube Banks
Air Preheaters
 FiredHeater Air Preheaters (Design
Considerations)

Many of the considerations for the convection section tube banks also apply to
air preheaters, particularly those relating to the cold end In considering the
impact of gas dew point it is important to consider the whole range of
operation - the gas will generally be coolest at minimum load, and on
occasion some form of bypass may be needed to ensure that the flue gas
stays above its dew point.
The maximum air preheat temperature found in process heaters is about 700
K (427°C) Above this temperature, the metallurgy of the ducting and the
burners begins to be affected, with a consequent increase in expense.

See also:
Air Preheaters (Principal Features)
 FiredHeater Horizontal or Helical Tubes (Design
Considerations)

Horizontal or helical tubes can be arranged in the firebox such that the
hottest process temperature (the outlet temperature) is away from the
regions of high heat flux (the process fluid is arranged to flow co-currently to
the combustion gases) This is not possible with vertical hairpin tubes, but on
the other hand horizontal tubes are more difficult to support, requiring more
structural parts within the hot firebox
Fabrication considerations tend to limit helical coils to around 4 m coil
diameter
With horizontal tubes it is important to avoid stratified flow regimes which
could lead to dryout in the top part of the tube.
 FiredHeater Vertical Tubes (Design
Considerations)

When using vertical hairpin tubes for liquid duties, it is important to avoid
pockets of gas or vapor collecting at the top of the tubes These can give rise
to a "hydraulic ladder" effect - as the vapor is pushed into the downlegs a
static head resistance equivalent to the height of each gas pocket develops In
severe cases this has been known to stop the flow through one or more coils
of a multipath heater, leading to overheating and eventual failure One way to
guard against this is to have a flow control on each path.
 FiredHeater Process Fluid Fouling (Design
Considerations)

Many fluids break down to form coke or lay down polymeric materials if
overheated For this reason, it is usual to try to avoid going through the
dryness point in regions of high heat flux, and a typical hydrocarbon vaporizer
is limited to 60-70% vaporization at the exit Mass fluxes in vaporizer tubes
are generally kept above 1000 kg/m2s.
 FiredHeater Refractory Backed or Central Tubes
(Design Consideration)

Wall-mounted refractory backed tubes are easier to support than central

tubes, but in very large heaters having all the tubes on the wall may lead to
an unacceptably large plot area When a very even heat flux is required, such
as in a cracking furnace, this is more readily achieved with a radiant wall
heater with tubes located in the centre of the furnace.
 Plate: Heat Transfer Resistance Diagram
The resistance diagram appears at the bottom of the Performances screens.
It shows the thermal resistance between the shell side and tube side streams
broken down into five components along the length of a horizontal bar.
The five resistances are
Shell Side stream
Shell Side fouling
Tube wall
Tube Side fouling
Tube Side stream.
By default, the stream resistances are yellow, the fouling resistances red, and
the wall resistance black.
Resistances are derived from mean heat transfer coefficients.
Thermal resistances are the inverse of heat transfer coefficients.
The Diagram provides an immediate indication of the largest resistance in the
system, which is the one where an improvement would have the greatest
benefit
 PlateFin: Application Options
The Application Options section includes the following screens:
Application Options
 PlateFin: Fraction of Maximum Heat Load
The maximum heat load for a stream in a multi-stream exchanger is the heat
load achieved by heating the stream to the maximum hot stream inlet
temperature (for cold streams) or by cooling the stream to the minimum cold
stream inlet temperature (for hot streams). Specifying the fraction of
maximum heat load in the program input is an alternative to specifying the
stream duty.
If you know the stream duty or outlet conditions that are expected, it is best
to specify those. For a simulation calculation for which you have little idea of
what the outlet conditions will be, then specifying the fraction of the
maximum heat load can be a useful input – for some or all streams.
The program output includes the calculated value of the heat load as a
fraction of maximum for each stream. This output from one Simulation case is
potentially useful as an input for variants on the case, in which stream flows
or inlet conditions have changed slightly.
If you have a two stream exchanger, and look at output value of the fraction
of maximum load for the two streams, then the larger of the two values
corresponds to what is often known as the “exchanger effectiveness”
Output values are in Thermal Performance – Streams.
 PlateFin: Pressure at Liquid Surface
(Thermosiphon)
For a thermosiphon reboiler or plate-fin kettle, enter the pressure at the
surface of the liquid which is providing the pressure head driving the flow. For
an external reboiler, this is the pressure in the column. For an Internal
reboiler or kettle, it is the pressure at the surface of the liquid in which the
exchanger is immersed.
The pressure at the liquid surface is the definitive pressure for
thermosiphons. The pressure at exchanger inlet, if specified, is simply an
approximation. The actual pressure at the exchanger inlet is calculated
allowing for gravity head, and for pressure losses in the inlet pipework, if any.
For a thermosiphon reboiler, the pressure in the column can also be defined
as a separate item in the “Thermosiphon” input. When either of these inputs
is specified, the other is set equal to it. You should use the input on the
Process Data sheet, as this is normally the input encountered first and
crosschecking with any other specified process conditions is straightforward.
 PlateFin: Layer Group (Crossflow)
This item will be used in future versions of PlateFin.
Layer groups are used when an exchanger has multiple crossflow passes, and
these passes are located at different parts of the layer stack, rather than at
different distances along a layer type. The different parts of the stack are
referred to as layer groups. Each Layer Type must be identified as belonging
to a particular layer group.
A layer type cannot be in more than one layer group. It will sometimes be
necessary to define multiple identical Layer Types, one for each layer group.

See also:
Number of Layer Groups
 PlateFin: Layer Type Schematic
The layer type schematic diagram appears on the layer type input tab. It is a
simple representation of all layer types, showing the location of all layer
elements in each type as a series of colored rectangles. It gives an accurate
representation of the specified length of all layer elements, but the width of
the layer types is purely schematic. The coloration is defined by stream
number, as shown in the key. Distributor elements are shown by rectangles
with a cross, as in the example below.
 PlateFin: Layer Element Types - more
information
Different layer element types are used for different types of flow, as in the
table below.

Inlet distributor (stream) number Axial flow only

Outlet distributor (stream) number Axial flow only

Main fin: fin number Axial flow only

End bar

Redistributor-outflow Standard Axial Flow exchangers only

Redistributor-inflow Standard Axial Flow exchangers only

Inlet intermediate distributor number Standard Axial Flow exchangers only

Outlet intermediate distributor number Standard Axial Flow exchangers only

Hardway fin Axial flow only

Inactive fin

X-flow main inlet: stream number C rossflow only

X-flow main outlet: stream number C rossflow only

X-flow finning: fin number C rossflow only

X-flow pass inlet: header number C rossflow exchangers only

X-flow pass out: header number C rossflow exchangers only

Multipass X-flow fin: fin number C rossflow only

Multipass X-flow: number of passes For multipass X-flow fin

Unspecified

In Standard Axial Flow exchangers, crossflow streams can be specified, but

are assumed to be relatively minor contributors to the overall heat transfer
and modeled approximately. Some of the layer element types are restricted to
either Standard Axial Flow exchanger or to Crossflow exchangers. See
Exchanger Types.

More information on each element type is given below.

End Bar
There is assumed to be an end bar at each end of a layer. This item is also
used for separator bars in mid exchanger. In special cases, such as full end
distributors, there may not physically be any end bar, but a "logical" end bar
should still be specified.
Inlet and Outlet Distributors
These refer to the distributors handling the main stream inlet and outlet.
Every axial flow stream in the layer must have one of each. More detailed
information must be given under the Distributors input, which in addition to
the normal range of geometries, with side or end entry/exit includes options
"none" and "header only".
The inlet and outlet distributors serve to identify the stream in the sequence
of elements between them. Strictly they identify the distributor number,
where the stream number is identified, but the distributor number and stream
number are identical in almost all cases. There is a distinction only when a
stream has different distributor geometries in different layers. See Number of
Distributor Types
When there is flow redistribution, these items should NOT be used for the
distributors where a fin enters (or leaves) a new set of layers. Such
distributors are termed "intermediate distributors". See below.
Main Fin
This refers to standard axial flow finning. It is identified by a number which
may be either a direct reference to the fin data input, or a fin number from a
User Databank.
A sequence of Main fins may be specified, where appropriate.
Hardway Fin
Hardway fin is a short length of perforated or serrated finning laid
transversely to the flow, usually immediately adjacent to the inlet distributor.
Its function is to give good distribution of the flow across the layer. Specially
adapted methods are used for heat transfer and pressure drop with hardway
fin.
Inactive Fin
Inactive fin is finning through which there is no flow, and hence does not
contribute directly to stream heat transfer or pressure drop. In layer by layer
calculations, however, conduction through inactive fin affects heat transfer
between streams in the layers either side of the hardway fin. Hardway fin
often forms a dead end, and its location is determined by drainage
considerations. It always occurs immediately below and end bar, often
between the end bar and a distributor.
X-flow Fin
Cross flow finning is for cross-flow streams. One such fin identifies one
crossflow pass across the full width of the exchanger. In crossflow exchangers,
specifying a sequence of X-flow fin (with no intervening headers) defines
multiple passes with internal turnaround.
X-flow fin is not normally used in Standard Axial Flow exchangers, although
occasionally a short length of such finning is used near one end of the
exchanger. When used with axial flow calculations, a modeling approximation
is used to compensate for any variation in temperature across the layer
width, which cannot be modeled explicitly. This approximation should be
reasonable where the temperature change of the stream in the cross-flow
layer is small, and the axial length of the crossflow layer is small compared to
the total exchanger length.
Multi-pass X-flow Fin
Multi-pass X-flow fin is a series of cross-flow fin regions connected by
triangular turnaround fin regions on alternate sides of the layer. This gives an
overall flow along (up or down) the exchanger. Since the width(axial length)
of the cross flow regions is less than the exchanger width, the net effect is to
give increased mass flux and heat transfer. It is useful when a purely axial
mass flux would be very low. The program allows not only for the increased
mass flux, but also for the increase in effective path length when determining
pressure drop.
Number of X-flow passes
This is a nominal (zero length) region, which must appear immediately after
Multi-pass X-flow fin. The crossflow width of each pass is the total axial length
divided by the number of crossflow passes.
In Crossflow exchangers, multi-pass crossflow is modeled fully, and there is
no problem specifying a small number of passes. In Standard Axial Flow
exchangers, the modeling methods give a better approximation when there
are a large number of passes.
Redistributor: Outflow
Redistributor Outflow refers to a dividing redistributor, which causes the part
of the flow in a layer to be diverted to a header and thence to another set of
layers. The flow fraction is determined by the assumption that after the
redistributor, the mass flux in the new layers is the same as that of the flow
remaining in the original layers. More information on the redistributor
geometry must be supplied in the Special Distributors input.
A redistributor is identified by a redistributor number, which by default is the
same as the stream number. This is however not a requirement. In the
(unusual) event of a stream having more than one redistributor along its
length, or two layer types with the stream using different redistributor
geometries to feed the same header, they can be given different redistributor
numbers.
Normally a redistributor header is blind (in other words, it has no nozzle).
Sometimes, however part of the flow is drawn of from the header. See:
Partial Draw-Off
Redistributor: Inflow
Redistributor Inflow is analogous with Redistributor Outflow, but refers to a
combining redistributor. This creates an additional flow in a layer type, by
taking the outflow flow from another set of layers via a header. It is
geometrically equivalent to a dividing redistributor, so the same geometry
information must be supplied in the Special Distributors input.
Inlet and Outlet Intermediate Distributors
In conjunction with each redistributor, (except with partial draw-off) there
must be an intermediate distributor. The dividing redistributors in one set of
layers will deliver flow to a header and thence to the inlet intermediate
distributor in another set of layers. A combining redistributor will accept flow
from the outlet intermediate distributor of another set. In principle, an outlet
intermediate distributor in one set of layers could deliver flow to the inlet
intermediate distributor in another set, without any redistributors being
involved.
Geometrically, intermediate inlet or outlet distributors can be identical to any
side entry/exit main inlet or outlet distributor. The key distinction is that an
intermediate distributor is used at some point along the exchanger length,
between the main inlet and main outlet distributors. The fluid flowing through
an intermediate distributor is not at the main stream inlet or outlet
temperature, but at some other temperature, which is determined when the
program is run.
X-flow main Inlet and Outlet
Crossflow streams have no distributors. The X-flow main inlet and outlet are
zero length elements which are logically equivalent to the inlet and outlet
distributors of axial flow streams. They relate to the overall stream inlet or
outlet, and point to Distributors which are of type “Header-only”. The
Distributors input is also where the header is identified as being on the left or
right hand side of the exchanger.
X-flow Pass Inlet and Outlet
The X-flow pass inlet and outlet are zero length elements which are logically
equivalent to the intermediate distributors of axial flow streams. They relate
to flow to or from intermediate headers between crossflow passes. They are
identified by a simple header number, rather than a distributor number. Their
location on the left or right hand side of the exchanger can be deduced from
their location in a crossflow pass sequence.
 PlateFin: Fin Databank
A Fin databank is a text file, which you can configure using whatever fin data
you have available. The databank can contain fin geometry and performance
data for a large number of fins, each identified by a fin number in the range
101 to 9999. When a fin is referred to in the program, its databank number
can be given, permitting the relevant data to be read in.
The format of the Fin Databank is identical with that used with the MUSE
program; the only difference is a minor change in filename. The databank file
is called FinData.txt and is stored in the directory where the file PlateFin.dll is
located, typically:
C:\Program Files\AspenTech\Aspen Exchanger Design and Rating V7.3\XEQ

For each fin, there is a set of data which begins with a line number in the 700
series, as in the example below. After the line number, there are up to six
data items on each line, separated by spaces. The first three lines identify the
fin and its geometry in metric units (mm, fin/m). The remainder (710 lines)
give the Re-f-Cj performance

KAYS AND LONDON (SURFACE 11.1)

701 FINS S KAYS/LON 11.1
702 136 1
703 6.35 0.15 437.01 0
710 500 0.03500 0.00840 800 0.02280 0.00599
710 1200 0.01690 0.00471 2000 0.01390 0.00436
710 2500 0.01190 0.00424 3000 0.01120 0.00412
710 4000 0.01030 0.00390 5000 0.00991 0.00372
710 6000 0.00971 0.00356 10000 0.00878 0.00314

The line 701 FINS S indicates the beginning of a new fin data set. Subsequent
characters on this line can be used for a fin name.
The 702 line gives the fin identification number, 136 in the above example.
The next item identifies the fin type: 1= plain, 2=perforated, 3=serrated and
4=wavy (herringbone). An optional third item gives the Prandtl number
correction flag.
The 703 line gives the fin height, fin thickness, fin frequency, fin porosity and
fin serration length. The last two items are only needed for the relevant fin
type. Omitted items can be indicated by an asterisk (*).
The 710 lines give Re-f-Cj performance data, with two sets of Re-f-Cj per line,
and up to eight such lines. It is wise to set up data for a wide range of
Reynolds number to cover all potential uses of the fin.
The 700 series line numbers may optionally be preceded by a single blank.
Lines beginning with an asterisk are ignored, as are any other unrecognized
lines. This can be used to document the bank, as in the first line in the
example above.
Two other features are not in the first release of PlateFin (V7.1):
· A line beginning NO WARN in the bank suppresses any warning
messages indicating that the Re-f-Cj data points are out of the expected
range.
· A sixth item on line 702 (after * s to indicate omitted preceding items)
can be set to 1 to indicate that the performance data relate to the hardway
orientation.
 PlateFin: UA Values
The UA value of a heat exchanger is derived from the relation between the
heat load Q and mean stream to stream temperature difference Dtmean.
Q = UA DTmean
It is calculated by integrating the inverse temperature difference with heat
load along the exchanger.
UA = integral (dQ / DT)
Simple UA value for an exchanger can be calculated from the composite hot
and cold heat load curves. These composite curves are derived from the heat
load curves for each stream, which show how temperature varies with
cumulative heat load (mass flow times specific enthalpy change) between
inlet and outlet.
The Simple UA is purely a thermodynamic quantity. It does not depend on the
size or geometry of the exchanger. It is normally calculated assuming pure
countercurrent flow but can equally be calculated assuming pure co-current
flow.
Since stream temperatures depend on both specific enthalpy and pressure,
setting up a heat load curve involves making some assumption about how
pressure varies between inlet and outlet. There are two basic options for
simple UA: pressure varying with temperature, or pressure varying with
specific enthalpy.
The real UA for an exchanger is determined using calculated individual stream
heat load curves within the exchanger (as against composites) and using the
calculated pressure variation. The real UA is thus an exchanger parameter
and can be thought of as a mean U-value (overall heat transfer coefficient)
times the exchanger area.
In most cases, the assumption of pressure varying with T (temperature) or
with h (specific enthalpy) makes minimal difference to the calculated UA.
Unfortunately, in some cases, the pressure assumption has a big effect, and
the simple UA becomes anything but simple.
Difficulties arise when one or more streams are pure components, or
azeotropes, or nearly so. In such cases, the heat load curve using the
assumption of pressure varying with enthalpy is not monotonic in the two
phase region. For example, a boiling stream will first increase in temperature
up to the bubble point, then decrease in temperature over the two phase
region, then increase again in the vapour region. If there is another stream
(of the same type, hot or cold) present over the two-phase temperature
range, this non-monotonicity means that the composite curve becomes ill-
defined. By definition, a composite curve has a single temperature at each
point. It cannot have one stream increasing in temperature and another
decreasing.
The assumption of pressure varying with temperature does not have the
monotonicity problem, since the bubble and dew point on the composite curve
will be at the same temperature and pressure. The downside is that this is
less realistic, since in practice the two phase region will often account for a
large fraction of the stream pressure change.
A compromise is to begin with “safe” assumption of pressure varying with
temperature, but if there is only one stream, to revert to the more realistic
assumption of pressure varying with enthalpy.
An alternative approach is to use the assumption of pressure varying with
enthalpy, and then to artificially eliminate any problem by increasing the
temperature of a cold stream, or decreasing the temperature of a hot stream,
in the region where the T(h) curve would otherwise not be monotonic.
PlateFin gives the option of calculating UA values assuming pressure variation
with temperature, or with enthalpy, or with the compromise of a basic
variation with temperature but reverting to variation with enthalpy for a
single hot stream, or a single cold stream. This input option is found under
Program Options | Thermal Analysis | Heat Transfer & Pressure Drop.
Any hot stream with an outlet temperature below inlet or cold stream with an
outlet temperature above inlet is automatically switched to pressure variation
with enthalpy to avoid monotonicity problems.
Selecting variation with enthalpy initially uses the technique of artificial
enforcement of monotonicity, followed by reversion to the true variation if
there is a single hot or single cold stream.
PlateFin records the (real) UA value for the calculated results in the Results
Summary, while in the Thermal-Hydraulic Summary output, under Solution
Overview | Special Options, it records both this calculated UA value and
two simple UA values, one for the initially specified duty, and one for the
calculated duty.
In Design Calculations, where the calculation is based on the simple UA and
the duty is fixed, all three UAs will normally be the same.
The Simple UA values assume pure counterflow, unless the initial specification
of the exchanger is purely co-current. Care should be taken with simple
crossflow exchangers, where the initial specification is deemed to be co- or
counter-current, depending on the sequence of the nominal crossflow inlet
and outlet headers, as defined in the Layer Type input.
If you want to compare the UA value from PlateFin with the value from
HYSYS, then the following points should be noted.
· The UA option Pressure variation with enthalpy should be selected.
· Properties data should be provided at a sufficient number of points, and
at least two pressures.
· Comparisons should be made with the Simple UA, not the calculated UA.
· Care should be taken if any stream is a single component.
· Care should be taken to match pressure changes, by using the option to
Check, rather than Simulate pressure changes.
· Remember UA does not tell the whole story. The UA may look OK, but
some streams may have more than their required duty, and others less.
 PlateFin: Calculation Control
A number of input items give you extra control over the calculation. The
default settings for all these items should normally be adequate, but you can
adjust them if there are convergence problems with the default settings.
The calculation is based on iterations at which the current heat load, defined
by stream enthalpy profiles along the exchanger, is updated using the
calculated heat load from heat transfer, determined by integrating the
product of local overall heat transfer coefficient and local stream to stream
temperature difference over the heat transfer surface of the exchanger.
A parallel calculation for pressure updates the current pressure at each point
in the exchanger using the calculated pressure change, based on pressure
gradients and changes at points within the exchanger.
There can be a series of calculations. Initially there is a Checking calculation,
then if required there is a stream by stream simulation, and finally, if
required, there is either a layer by layer calculation, or a set of thermosiphon
calculations, which iterate to find the thermosiphon stream flowrate. The
series of calculations stops at the point appropriate to the main calculation
being performed. The iteration counter is reset to zero at the beginning of
each set. Calculation control variables in most cases relate to all the
calculations in the series.

a) Maximum number of iterations.

The maximum number of iterations can be increased to improve convergence
in hard cases.

b) Convergence tolerance
Separate convergence tolerances can be set for heat load and pressure. The
tolerance is the different between current and calculated values of heat load
or pressure at the exchanger outlet, expressed as a fraction of the current
value.
For Checking calculations, where the heat load or pressure change are
specified as being constant, the definitions are adapted, so that, for example
fractional change in area ratio, rather than heat load is significant.

c) Relaxation Parameter
The basic heat transfer calculation involves updating the current heat load
profile using a value calculated from the predicted heat transfer. The
relaxation parameter R is used in the relation
Updated value = (1-R) x Current value + R x Calculated value.
For calculation stability reduced values of R are used in early iterations, or if
potentially difficult convergence situations are encountered. The value here is
used when convergence is proceeding normally. A lower input scales down the
reduced values early in the calculation as well. For cases which fail to
convergence, a reduced convergence parameter (and/or higher resolution)
may help, but at the expense of more iterations being needed.

d) Convergence Criterion.
The standard criterion for convergence is that both the pressure change and
heat load calculations must have converged to the specified accuracy, but less
restrictive conditions can be imposed if desired. It is also possible to specify
that the calculation proceeds beyond convergence, to the specified maximum
number of iterations. This can help double check that true convergence has
been achieved, rather than a slowly drifting in an approximation to
convergence.

e) Calculation Step Size

This input provides an additional control on the (relative) size of the changes
to the current heat load from one iteration to the next.. It will mainly have an
effect early in the calculation when changes are large. Setting a small value is
equivalent to an additional reduction in relaxation parameter when the
calculation is far from convergence.
 PlateFin: Flow Distribution Specification
With Layer by Layer calculations, you can specify a flow distribution among
the layers for one or more streams in order to investigate what effect this has
on thermal performance.
There are three options:
· Flow Distribution: % Excess (assume a linear or parabolic variation of
flow across the exchanger, by specifying a %excess in the first and last layers
of the stream)
· Flow Distribution: All Layers (specify the (relative) flow in every layer of
a stream)
· None: (the default for all streams: maintains a uniform flow distribution
of the stream among all its layers)

See also:
Flow Distribution Calculations
 PlateFin: Flow Distribution: All Layers

This option for specifying the distribution of flow among layers uses two sets
of inputs.
Total Specified Layer Flow
Stream / Flow table

The Total Specified Layer Flow defaults to the number of layers in which the
selected stream is present.
The Stream / Flow Table is populated by relative flows in each layer. The first
column in the table gives the stream number (which you cannot change). The
default values, corresponding to uniform flow, are then 1.0 in each layer.
These represent layer in the layer pattern, which contain the stream at inlet,
reading from left to right in the pattern. These layers are grouped in sets of
ten, so streams with more than ten layers occupy more than one line in the
table.
When you modify the relative flow in any layer, the default flows in all the
layers are re-calculated, so that the total specified flow is maintained. An
error condition is generated if you specify a set of flows which adds up to
more than the specified total flow (number of layers).
The Total Specified Layer Flow can be reset form the default value. This
causes all the values in the Stream / Flow table to be scaled accordingly. You
could, for example, set the total flow to be the actual stream flow (in
whatever units you chose); however, this is only advisable when all the layers
in which the stream enters the exchanger have the same height.
If a stream flows in layers with a different layer height, then the default
relative flows will still always be one. The flow you specify is the flow relative
to uniformly distributed flow, where “uniform distribution” allows for extra
flow in higher layers. When you change an input, allowance for relative layer
heights is made in calculating defaults.
Select all the streams for which you want to input a flow distribution before
entering any relative flow values. This makes it clear which lines in the table
apply to which stream. If you do make a mistake and enter a set of flow
values which you would like to move up or down the table, copy the entire
table to Excel, then select the set of values you want to re-locate, and paste
them back into the table.

See also:
PlateFin: Flow Maldistribution
PlateFin: Flow Distribution: % Excess
 PlateFin: Flow Distribution: % Excess
This option offers two inputs:
Flow Excess (%) in first layer
Flow Excess (%) in last layer

When performing layer-by-layer simulations, this is the simplest way to

specify how the flow of each stream is distributed among the layers through
which it flows. The default assumption is uniform distribution, but you can
alternatively specify a linear or parabolic distribution among the layers of a
stream. This might represent the effect of the way header pressure changes
are different for the layers near and far from the inlet/outlet nozzles.
If you specify a +ve flow excess in the first layer and the corresponding –ve
excess (i.e., reduction) in the last layer, then the flow distribution will vary
linearly across the exchanger layers for this stream.
If you specify the same +ve excess in both the first and last layers of a
stream, then by implication there will be a (parabolic) minimum in the
intervening layers to achieve the correct overall average flow. Similarly, a –
ve excess at the two ends implies a parabolic maximum in the layers between
the ends.

See also:
PlateFin: Flow Maldistribution
PlateFin: Flow Distribution: All Layers
 PlateFin: Area Ratio
An area ratio can be defined for each stream in a PlateFin exchanger. This
term is more familiarly used with shell and tube exchangers. It is the ratio of
the actual stream heat transfer area to the area required for a specified duty.
For two stream exchangers such as shell and tube, the ratio must be the
same for both streams and is taken as a simple measure of the acceptability
of exchanger performance. An area ratio of above one is taken to mean that
an exchanger can more than achieve a specified duty.
In a multi-stream exchanger, the position is more complicated, since each
stream can have a different area ratio. An area ratio above unity does not
necessarily indicate that all the area is in the right place to achieve the
desired heat transfer. Nevertheless, the area ratio can be useful as one more
parameter indicating how well an exchanger is performing.
Area ratios are the primary result of Checking calculations. For two stream
exchangers, the area ratio of each stream will be the same.
For a Simulation calculation, the area ratio should in principle be unity.
Values slightly different from unity sometimes occur when the overall heat
load (based on stream exit conditions) has converged more rapidly that the
local stream heat transfer at all points between inlet and outlet.
 PlateFin: Layer Pattern (expanded)
The Layer Pattern is provided in expanded form as a set of text strings,
showing layers of each type on a separate line. The pattern is provided for
either the whole exchanger or half the exchanger, depending on what was
specified for the pattern in the input.
If the exchanger has more than two layer types, a simplified version of the
expanded pattern is given above the main expansion. The top line shows all
the hot stream layers, and the second line all the cold stream layers. A third
line shows any layers which are completely empty or which include both hot
and cold streams.
The fourth line from the top provides a method of counting the layers. An
integer value is given every ten layers, 1 at layer 10, 2 at layer 20 etc.,
beginning again with 0 for layer 100, and 1 for layer 110. Between the
integers counting decades, there is v, indicating counts terminating in 5.
 PlateFin: Layer Occupancy
The Layer Occupancy diagram is provided in text form, reflecting an output
given in the earlier MUSE program. It provides a simple overview of the
structure of the various layer types and how these align with each other.
One line of text (100 characters) is given for each layer in turn. In each
layer, an integer, 1, 2. etc. is given where there is main finning with stream
1, stream 2, etc. The region occupied by inlet distributors is indicated by a
capital D and outlet distributors by lower-case d. Intermediate inlet and
outlet distributors are also indicated by D and d Redistributors are indicated
by R.

See also:
Layer Types
 PlateFin: Redistributors
A redistributor is used when, partway along an exchanger, part of a stream is
taken out of the exchanger and then fed back into an additional set of layers
which would otherwise be empty in that region. The special layout of fining
which achieves this split is termed a redistributor. The fining leading into the
additional layers is termed a re-inlet distributor.
The same terms also apply to combining redistributors, where the additional
layers are adjacent to the inlet region of a stream, and partway along the
exchanger the number of layers the stream occupies is reduced back to the
basic number. Combining redistributors are identified in the program input by
specifying the number of extra layers as negative.
A further alternative is partial draw-off, where the fraction of the stream
taken out from the redistributor is removed from the exchanger entirely. No
extra layers are involved in such a case, but you must specify the mass
fraction of the stream removed. For two phase streams, the quality of the
fraction removed is assumed to be the same as for the fraction remaining.
Redistributors normally have a special geometry involving three fin pads.
Pads 1 and 2 redistribute the flow that remains in the same set of layers, pad
3 takes the flow to (or from) the header that connects with the re-inlet
distributor. The orientation of the distributor is deduced from the flow
direction and the type of re-inlet distributor. The re-inlet distributor, within
the extra layers, can be any of the standard side entry/exit types, but is most
commonly type 4. This means that it can occupy the same portion of
exchanger length as the type -4 distributor of the stream which is replaced in
the extra layers.
Other possible redistributor layouts include the twin-headed version and
hardway re-distributors (single or twin headed). All these variants can be
modeled. Hardway redistributors consist of a single pad, so fin pads 2 and 3
need not be specified.
 PlateFin: Modeling Crossflow Exchangers
Crossflow exchangers are modeled using a two dimensional grid of points,
along and across the exchanger, whereas standard axial flow exchangers use
a one dimensional grid along the exchanger length. The number of points
along the exchanger is determined indirectly via the grid resolution input
(low/medium/high/very high) on the Calculation Options | Convergence
tab. The number of axial points for each setting, however, is lower for
crossflow exchangers than for axial flow exchangers.
The number of calculation points across the exchanger appears on the same
tab. It can be input explicitly, but use of the default (which varies with grid
resolution) is normally recommended.
The two dimensional grid is rectangular. Grid points across the exchanger are
located at the extreme right and left hand sides, with equal spacing in
between. Each represents an equal fraction of the exchanger width, except
the extreme left and right hand points which represent half this fraction.
Grid points along the exchanger are not uniformly spaced, but their location is
adjusted according to the size of various layer elements. See Modeling Axial
Flow Exchangers
The number of axial calculation points in a crossflow exchanger is lower than
it would be in an axial flow exchanger, with the same grid resolution
(low/medium/high/very high) but the total number of calculation points will
be significantly larger. Some adjustment is made to the number of axial
points in a crossflow exchanger so that there are more points when the axial
length is much larger than the exchanger width.
When there are multiple crossflow passes with internal turnaround, then
there is a further constraint on the number of axial points. There must be the
same number of axial points in each crossflow pass – even in the (unusual)
event of the pass axial lengths (flow widths) being unequal. This is because
with internal turnaround, flow at the top of one pass must go to the bottom of
the next pass, and vice versa. Each set of cross-flow points (at an axial
location) in one pass must map to a similar set of crossflow points (at another
axial location) in a subsequent pass.
The number of axial points in each crossflow pass is selected to be an odd
number to facilitate output representing flow along the middle of the pass, as
well as flow along the top and bottom of the pass.
The requirement to have matching sets of points in each crossflow pass with
internal turnaround can occasionally impose a constraint on the complexity of
an exchangers which can be modeled. When this happens, a fatal error
occurs, suggesting you amend the way the exchanger is modeled. An example
might occur when an axial flow stream, exchanging heat with a crossflow
stream with internal turnaround, has a change of fin type. If this change of fin
type occurs at an axial location corresponding to the middle of a crossflow
pass, there will be a fatal error. If the fin transition is relocated to occur at
the same point as the transition between crossflow passes, there will be no
problem.

See also
Specifying Crossflow Exchangers
Numbering Grid Points
 U-Bend Details and Totals
U-bend details output appears only when you specify a "Rear Head Type" of U
and specify a "Straight Length for U-tubes". The program determines the first
(smallest) bend diameter from the "Minimum U-bend Diameter" in the input.
Schedule number
This is merely a sequential number to identify a set of equal length tubes.
Bend diameter
This is the diameter through the center of the tube in the bend. It is equal to
the distance between the tube centers of the two straight length portions of
the U-tube.
Number of U’s
This is the number of U-tubes of the corresponding bend diameter and length.
U-tube length
This is the developed length from tube end to tube end through the center of
the tube and bend. It is the length of the straight tube before being bent to
form the U-tube.
Total length in U-bends & total straight length
These are the total length of tubing in the U-bends and the total length of
tubing in the straight lengths for the U-tubes.
Total length of all tubes
This is the total length of tubing (U-bends plus straight length).
 Shell&Tube Shell Type
The shell type determines the shell side flow arrangement and the place of
the shell side nozzles. The default is type E (except K type shell side pool
boilers).
E Generally provides the best heat transfer but also the highest shell side
pressure drop. Used for temperature cross applications where pure counter
current flow is needed.
F This two pass shell can enhance shell side heat transfer and also maintain
counter current flow if needed for temperature cross applications.
G Will enhance the shell side film coefficient for a given exchanger size.
H A good choice for low shell side operating pressure applications. Pressure
drop can be minimized. Used for shell side thermosiphons.
J Used often for shell side condensers. With two inlet vapor nozzles on top
and the single condensate nozzle on bottom, vibration problems can be
avoided.
K Used for kettle type shell side reboilers.
X Good for low shell side pressure applications. Unit is provided with support
plates that provides pure cross flow through the bundle. Multiple inlet and
outlet nozzles or flow distributors are recommended to assure full distribution
of the flow along the bundle.
D Double Pipe exchanger
M Multi-tube Hairpin exchanger
 Shell&Tube Tubesheet Type
The tubesheet type has a very significant effect on both the thermal design
and the cost.
The default is normal single tubesheet(s).
Double tubesheets are used when it is extremely important to avoid any
leakage between the shell and tube side fluids. Double tubesheets are most
often used with fixed tubesheet exchangers, although they can also be used
with U-tubes and outside packed floating heads.
Double tubesheets shorten the length of the tube which is in contact with the
shell side fluid and therefore reduce the effective surface area. They also
affect the location of the shell side nozzles and the possible baffle spacings.
The gap type double tubesheet has a space, usually about 150 mm (6 in.),
between the inner (shell side) and outer (tube side) tubesheets. The integral
type double tubesheet is made by machining out a honeycomb pattern inside
a single thick piece of plate so that any leaking fluid can flow down through
the inside of the tubesheet to a drain. This type is rare, since it requires
special fabrication tools and experience.
 Shell&Tube Tube to Tubesheet Joint
Select the type of joint used to attach the tubes into the tubesheet holes.
This input does not affect the thermal calculations, but does affect the cost
calculation.
 Shell&Tube Tube Type
Plain
Lowfin tube
Longitudinal fin
KHT Twisted Tube
Internal Enhancement

Selecting Lowfin, Longitudinal fin, KHT Twisted Tube, or Internal

Enhancement will cause a new tab to be displayed.
 Shell&Tube Tube Outside Diameter
Enter a value or select a standard tube outside diameter from the drop down
list.
See Also:
Tube Diameters
Common Bare Tube Diameters and Gauges
 Shell&Tube Tube Wall Thickness
Enter a value or select a standard tube wall thickness from the drop down list.
See also
Common Bare Tube Diameters and Gauges
The starting reference temperature is required if you are referencing the
databank at a single temperature or at a range of temperatures.
The pressure should be specified as absolute pressure, not gauge pressure.
The program uses the pressure value in order to adjust the gaseous
properties for the effect of pressure.
Enter the ending temperature if you are referencing the databank over a
range of temperatures or requesting a vapor-liquid equilibrium curve.
 Shell&TubeMech: Type of Bolt
The following different types of bolt can be selected:
· US – TEMA Table D-5
· Metric – CODAP
· DIN neck-down bolt
· TEMA Metric – TEMA Table D-5M
· PD5500 Metric – PD 5500 Table 3.8-2 (Metric)
· EN 13445 Metric – Annex G Table G.8.2 (Metric)
By default, the program will select a type of bolt relevant to the selected
Design Code.
Refer to Appendix – Bolt Data for full details of bolt stress areas and bolt
clearances.
 Shell&Tube Design Code
ASME (American)
CODAP (French)
AD-Merkblätter (German)
EN 13445 (European)
The Design Code is used to tell the program which basic mechanical design
calculations to follow and also to make the heat exchanger specification more
complete by calculating the following components:
· Required thicknesses for the shell and heads, therefore affecting the
number of tubes
· Thickness of the tubesheet, therefore affecting the effective heat transfer
area
· Dimensions of the flanges and nozzle reinforcement, therefore affecting
the possible nozzle and baffle placements
Due to the fact that the mechanical design calculations themselves are very
complex, the Shell&Tube only includes some of the basic mechanical design
calculations. The full calculations are the function of Shell&TubeMech.
 Physical Property Data: Import from HYSYS

A PSF file contains process and properties information for a heat exchanger in
a form suitable for importing into any Aspen EDR heat exchanger product,
such as Shell&Tube, AirCooled, Plate, PlateFin, and FiredHeater.
To Import a PSF file, you first need to select the heat exchanger unit
operation for which it should be generated, as shown in the form above. By
default, the stream data table displays the temperatures and pressures
associated with the selected unit operation. These determine the temperature
and pressure range of properties data to go in the PSF file, and these ranges
can be edited. Then click Import to continue the import process.
The designations Inlet and Outlet temperature for each side on the form
define the temperature range over which properties data are provided. You
can change these temperatures to change this range without changing the
exchanger inlet and outlet temperatures. For example, you can change the
outlet temperature end of the range to allow for the EDR simulation
predicting a greater temperature change than the HYSYS specification.
A PSF file can contain isobaric properties data at up to five pressure levels. At
present, HYSYS cannot go to more than three pressure levels. You can modify
the pressure levels, or you can delete one or more levels. However, you
should adjust what levels are present to be in either increasing or decreasing
order, so that the blank levels all follow the specified levels. Even if you think
the pressure change in the exchanger will be very small, it is advisable to
ensure a significant difference between the pressure levels.
You can also specify a target number of temperature points at which
properties are to be generated at each pressure level. The default is 12, the
maximum is 24. The EDR program will do calculations at a much larger
number of points, interpolating the properties points to provide values as
required. For a simple liquid or vapour stream, or for an isothermally boiling
or condensing stream, 12 points is often more than adequate. For other two-
phase streams, particularly if the exchanger has a very tight temperature
approach between streams, more points are sometimes useful.
There is no absolute link between the temperature and pressure range over
which properties data are provided for a side, and the range encountered by
that stream in the exchanger. It is simply sensible that the two ranges more
or less coincide to improve the accuracy of interpolation and to reduce the
need for extrapolation.
Note: Condensers and reboilers imported from Aspen HYSYS or Aspen Plus
with any efficiency set to any value other than 1 will produce different results
in EDR because this sort of efficiency is not carried over to the EDR model.
 Physical Property Data: Import from Aspen Plus

This dialog box is displayed when importing process and properties

information from Aspen Plus and Aspen HYSYS (the simulators). This import
uses a PSF file which contains process and properties information for a heat
exchanger, in a form suitable for importing into any Aspen EDR heat
exchanger product, such as Shell&Tube, AirCooled, Plate, PlateFin, and
FiredHeater.
To import a PSF file, first select the heat exchanger block in the upper list; C-
140 condenser is selected in the example above. Temperature and pressure
information for the selected block is displayed in the Stream Data table. By
default , the Stream Data table displays the inlet and outlet temperatures and
pressures of the selected block. If the block does not have a pressure drop, a
default pressure drop is used. By default a third, intermediate pressure is
added. The temperature and pressure information determine the range of
properties data written to the PSF file. These ranges can be edited. Then click
Import to continue the import process.
When the import is from Aspen Plus, additional information is extracted and
displayed for the block. This includes the block type, its solve status, and any
block comments.
To view the data that will be exported in the PSF file, click Generate PSF to
generate the psf files for each block. The files are created in the same folder
as the Aspen EDR (or simulators) case.
The Inlet and Outlet temperature for each side on the form define the
temperature range over which properties data are provided. You can change
these temperatures to change this range. You will not change the exchanger
inlet and outlet temperatures (the Process Data in Aspen EDR). For example,
you can change the outlet temperature of the range to allow the EDR
simulation to predict a greater temperature change than the simulators
specification.
A PSF file can contain isobaric properties data at up to five pressure levels. At
present, the Aspen Plus default to three pressure levels and HYSYS defaults to
two; neither simulator will generate more than three. You can modify the
pressure levels but take care that all levels present are in either increasing or
decreasing order. Even if you think the pressure change in the exchanger will
be very small, you should ensure there is a significant difference between the
pressure levels. If you want fewer pressure levels you can select which ones
you want in the Import from PSF dialog.
You can also specify a target number of temperature points at which
properties are to be generated at each pressure level. The default is 12, the
maximum is 24. The EDR program will do calculations at a much larger
number of points, interpolating the properties points to provide values as
required. For a simple liquid or vapor stream, or for an isothermally boiling or
condensing stream, 12 points is often more than adequate. For other two-
phase streams, particularly if the exchanger has a very tight temperature
approach between streams, more points can be useful.
The actual temperature range of points in the PSF file may be larger than you
specify, and the number of temperature points may also be slightly different
(larger or smaller), because the PSF File generator will make changes which
improve the EDR program’s ability to interpolate or extrapolate the properties
data.
In summary, the temperature and pressure ranges for properties data can be
changed but should more or less coincide with the expected temperature and
pressure range encountered by that stream in the exchanger. This improves
the accuracy of interpolation and reduces the need for extrapolation.
Note: Condensers and reboilers imported from Aspen HYSYS or Aspen Plus
with any efficiency set to any value other than 1 will produce different results
in EDR because this sort of efficiency is not carried over to the EDR model.
 Physical Property Data: Import from PSF

PSF files can be generated by process simulators and contain process and
properties information for some specified heat exchanger. When a PSF file is
imported, a screen such as that above will appear, giving key information for
each stream in the exchanger. The Stream Name and Inlet and Outlet
temperatures provide information to help you identify the stream. The screen
above lets you select how much information you want to import into your EDR
case.
For Shell&Tube, the default settings should be correct, and normally you just
click OK to import both process and properties data for both streams in the
exchanger.
Under Import to, you see either the name of the stream or a stream number
in an EDR case, or the designation Hot side(stream1) or Cold Side(stream
2) for Shell&Tube. You can ignore if you do not want to import the data into
EDR. For a multi-stream heat exchanger, you must take care to match the
stream number (exchanger geometry) to the correct process stream.
A PSF file normally contains isobaric properties data at two or three pressure
levels (anything from one to five is possible). You can elect only to import
data at some of these pressure levels. Use the drop-down list in Use
Properties and select one of the following options:
· All imports all property data
· 1(of n) imports the center-most pressure level
· 2(of n) imports the first and last pressure levels
· Special displays a dialog box for selecting individual pressure levels to
import
Selecting the Separate Process and Properties data check box gives you
the option of importing only Process data, or only Properties data.
 Shell&Tube Number of Tubes plugged
Enter the number of Tubes which are plugged (blocked off).
The total number of tubes specified is used to determine the shell side layout
and flow areas for shell side flow. The heat transfer area is however
determined from the total number of tubes less the number of plugged tubes.
The default for this item is zero, in which case there is not distinction between
the actual number of tubes, and the number of thermally active tubes.
Blocked off tubes are assumed to be uniformly distributed among the various
passes in an exchanger. They are also allocated an arbitrary location within
each pass, so they appear on the Tube Layout diagram as greyed in circles.
If you use the Pass Details option for tube layout, you can identify the
number of plugged tubes in each pass. Again, an arbitrary location will be
allocated to each plugged tube.
To set the location of plugged tubes correctly, select Use Existing for the
tube layout option. With this option, the layout can be edited before you run.
When you right-click a tube, you get the option to mark or unmark as
plugged. Unmark incorrect locations, mark correct locations, then re-run.
Only the number of plugged tubes in a pass affects the calculated results, not
the actual location of the tubes.
See Also:
Plugged Tubes
 Shell&Tube Wall Specification
Tubing can be supplied to either a Minimum Wall or Average Wall
specification.
Minimum Wall requires that the tube thickness shall not be less than the
specified thickness.
Average Wall permits the tube thickness to vary above or below the specified
thickness. This variance or tolerance may be up to 12% of the specified
thickness.
 Shell&Tube Tube Material
Select from the drop down list the required tube material type.
 Shell&Tube Tube Surface
The relative roughness of the inside tube surface affects the calculated tube
side pressure drop. The default value is smooth, which is what is normally
appropriate to heat exchanger tubes for process industry applications, and has
been recommended following consultations with the HTFS Tubular Exchangers
Review Panel. Commercial pipe will normally give an overprediction of what is
found in heat exchanger and should not be used unless you have reason to
believe your tubes are exceptionally rough.
These tube roughnesses are only used for single phase flow. All two phase
flow correlations for pressure drop are based on modifying the smooth tube
friction factors.
It is also possible to specify an explicit tube wall roughness. This should be
done with caution. Neither the smooth tube nor commercial pipe curves
match up with any fixed roughness value.
 Shell&Tube Tube Wall roughness

You can specify an explicit tube wall roughness, though this facility should be
used with caution. Neither the smooth tube nor commercial pipe curves match
up with any fixed roughness value.
Typical roughnesses are sometimes published for various types of tube. Two
random examples are
· 0.025mm, for new steel tubes (from The Heat Exchanger Design
Handbook)
· 0.15mm, for steel tubes cleaned after long use (from the Wärmeatlas)
When specifying a roughness, make sure you have appropriate units selected.
The units conversion utility might give poor conversion accuracy with very
low lengths.

See also:
Tube Surface
 Shell&Tube Tube Cut Angle
The tube end cut is defined as the acute angle of the cut from the tube axis
(that is from the vertical). The default is 90 degrees (square cut). Values
down to 15 degrees are permitted
The angle of the tube end cut at the bottom of the tubes affects the calculated
flooding velocity in reflux condensers. You can increase the flooding velocity
by extending the bottom of the tubes through the tubesheet and cutting them
at an angle.
 Shell&Tube: Recalculate Properties

This input item controls whether properties are recalculated for the specified
components, compositions, and temperature range every time you select
Run. The default is No, so if you load a case with properties calculated on a
previous version of a properties package, the previous properties are
retained. This default No is a change of functionality, introduced in V7.3.2.0.
Properties can be regenerated at any point by selecting a stream and clicking
Get Properties. See Physical Property Data Overview.
If you click Run and the program detects that no properties have been
generated for any stream, then properties are regenerated (for all streams),
regardless of the value of this input item.
This input item was introduced in part to accelerate calculation times.

See also:
Application Control
 Shell&Tube: Repeat Messages

This option controls whether the program lists all error or warning messages
relating to a single class of input, or a smaller number of messages with an
indication of how many similar repeat messages which have been suppressed.

See also:
Application Control
 Shell&Tube: Full Output

This input item helps improve calculation times when the program is run with
a process simulator. It is switched off on all Simulator iterations except the
final one. This eliminates the time taken to transfer unnecessary results back
from the calculation engine to the Simulator.
When the program is run standalone, this item should not be set by the user.
This input item was introduced to accelerate calculation times.

See also:
Application Control
 Shell&Tube: Use Phase Compositions

This input item helps improve calculation times when the program is run with
a process simulator. It is switched off on all Simulator iterations except the
final one. This eliminates the time taken to transfer unnecessary phase
compositions (in the properties input) from the simulator to the engine, and
to transfer unnecessary inlet and outlet phase flow and composition
information back from the calculation engine to the Simulator.
When the program is run standalone, this item should not be set by the user.
Note: Phase composition inputs are needed when the mass transfer method
is used for multi-component condensation. This method is however inherently
slow, and using it when Shell&Tube is run from a Process Simulator is unwise.
Phase compositions in the properties input are also interpolated to give the
phase compositions (and hence phase flows) at the exchanger inlet and outlet
conditions. This information is however available from directly calculated inlet
and outlet phase compositions when the program is run with a Simulator, so
there is little value in supplying interpolated values from Shell&Tube.
This input item was introduced to help speed up calculation times.

See also:
Application Control
 Shell&Tube: Calling Program
This input indicates the calling program. It helps accelerate calculation times
by eliminating unnecessary calculations and data transfers when the program
is called directly from a process simulator, such as Aspen HYSYS or Aspen
Plus.
This input is set to Standalone when the program is run from the standard
user interface.

See also:
Application Control
 Physical Property Data Aspen Property Method
The available Property Methods are grouped below into recommended
Property Methods per Process Type:
Process Type - CHEMICAL
Process Type - COALPROC
Process Type - COMMON
Process Type - ELECTROL
Process Type - ENVIRON
Process Type - GASPROC
Process Type - HF-ACID
Process Type - METAL
Process Type - OIL-GAS
Process Type - PETCHEM
Process Type - POLYMER
Process Type - POWER
Process Type - REFINERY
Process Type - SYNFUEL
Process Type - WATER

For two-liquid phases:

Process Type - Chemical systems
Process Type - Hydrocarbon systems
 Physical Property Data Aspen Free-Water
Method
IAPWS-95
IDEAL
STEAM-TA
STEAMNBS
STMNBS2
SYSOP0

This option lets you specify the property method for the free-water phase.
Steam tables are recommended. Two methods are available for the properties
of steam and water:
STEAM-TA 1967 ASME Steam Tables
STEAMNBS The method of the International Association of Properties of
Steam

For process calculation purposes, the accuracy of both methods is adequate.

STEAM-TA method is made up of different correlations each covering different
regions of the PT space. These correlations do not provide continuity at the
boundaries which can cause spurious convergence problems. It can also
predict wrong trends. For example, the vapor phase enthalpy decreases at
pressure of 119 bar and temperature around 320-330C. This abnormal
behavior will cause a flash convergence failure. STMNBS2 can also have this
problem.
Since STEAMNBS does not have this problem and it also extrapolates better,
it may be wise to use it instead of STEAM-TA for pure water streams and for
free-water calculations, unless there are other considerations to be taken in
account. For similar reasons, it is usually best to use STEAMNBS for Property
Methods such as SRK that calculate water properties from the Free-Water
Property Method.
 Physical Property Data Aspen Water Solubility
Lets you select the calculation method for solubility of water in the organic
phase.
This method affects the K-value of water between the organic liquid phase
and the vapor phase. If you select: ‘Water solubility option’ then the Aspen
Physical Property System calculates the K-value of water from:
0 Water-solubility correlation with vapor phase fugacity of water. Calculated
by free-water phase property method.
1 Water-solubility correlation with vapor phase fugacity of water. Calculated
by the primary property method.
2 Method 1, but include activity coefficients correction. Recommended for
unsaturated systems.
3 Primary property method. The appropriate binary interaction parameters for
water are required.
4 Method 2, but water solubility limit is 1. Intended for VLE systems where
the liquid phase is predominantly water.
5 Method 2, but vapor phase fugacity calculated by the free-water phase
property method as in method 0.
 Physical Property Data Aspen Flash Option
Phases used in flash calculations.
 Physical Property Data BJAC - VLE Calculation
Type
Integral
Differential

Integral condensation implies all vapor and liquid remain in intimate contact
throughout the process. Differential condensation implies the liquid is
separated from the vapor.
The program defaults to integral.
 Physical Property Data BJAC - VLE Calculation
Method
Ideal
Soave-Redlich-Kwong
Peng-Robinson
Chao-Seader
Uniquac
Van Laar
Wilson
NRTL

Select the VLE method to be used in calculating the properties.

 Shell&Tube Front Head Type
The front head type should be selected based on the service needs for the
exchanger. A full access cover provided in the A, C, and N type heads may be
needed if the tube side of the exchanger must be cleaned frequently. Type B
(default) is generally the most economical type head.
The Front Head can also be referred to as the Stationary Head or Fixed Head.
 Shell&Tube Rear Head Type
The rear head type affects the thermal design, because it determines the
outer tube limits and therefore the number of tubes and the required number
of tube passes.
 Shell&Tube Exchanger Position
Specify whether the exchanger is to be installed in the horizontal or vertical
position.
The default is vertical for tube side thermosiphon; for all others, horizontal.
 Shell&Tube Shell(s) - ID
Enter the Inside Diameter of the Shell Cylinder.
If the Shell Cylinder is to be made from Pipe, it is recommended to leave this
input blank, and enter a value for the Shell Outside Diameter.
If a Kettle Shell is to be used then enter the Inside Diameter of the Shell
Cylinder at the Inlet Tubesheet.

Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Shell(s) - OD
Enter the Outside Diameter of the Shell Cylinder.
If the Shell Cylinder is to be made from Plate, it is recommended to leave this
input blank, and enter a value for the Shell Inside Diameter.
If a Kettle Shell is to be used then enter the Outside Diameter of the Shell
Cylinder at the Inlet Tubesheet.

Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Shell(s) - Series
In Rating/Checking or Simulation or Maximum Fouling modes, enter the
number of shells (or sets of parallel shells) in series.
The default is one exchanger (shell) in series.
For all modes, the maximum number is 12 for E, I, J shells or 6 for D, F, G, H
and M shells. Only one shell in series is permitted for K and X shells.
In order to specify a hairpin multi-tube exchanger or a hairpin-type double
pipe exchanger, (M- or D-type), where one exchanger consists of two shells in
series, enter the number of Exchangers in series. The number of tube side
passes per shell in such exchangers is one.
In Design mode, values can be set for Minimum and Maximum Number of
Shells in Series
 Shell&Tube Shell(s) - Parallel
In Rating/Checking or Simulation or Maximum Fouling modes, enter the
number of shells in parallel.
For all modes, the default is one exchanger (shell) in parallel, and the
maximum number allowed is 50.
In order to specify a hairpin multi-tube exchanger or a hairpin-type double
pipe exchanger, (M- or D-type), where one exchanger consists of two shells,
enter the number of Exchangers in parallel. The number of tube side passes
per shell in such exchangers is one.
In Design mode, values can be set for Minimum and Maximum Number of
Shells in Parallel.
 Shell&Tube Baffles - Spacing (center-center)
In Rating/Checking or Simulation modes, enter the spacing between the
centers of adjacent baffles.
In Design mode, enter the maximum baffle spacing to be considered during
the design process. If defaulted in Design, the maximum baffle spacing is set
to equal the shell inside diameter.
Note:
Front Head End Length + Rear Head End Length + Baffle Spacing x (Number
of Baffles - 1) = Tube Length. The program will check this and make
corrections if necessary.
For RODbaffle exchangers, the baffle spacing may be 3, 6, or 9 inches (76.2,
152.4 or 228.6mm)

As the Bundle Geometry varies with unit type, refer to the following sections
for detailed diagrams of each combination:
U-Tube
Fixed Tubesheet
Floating Head

Note the following special cases:

`F' Shell Type
`G' Shell Type
`H' Shell Type
`I' Shell Type
`J' Shell Type
 Shell&Tube Baffles - Number
Enter the number of Transverse Baffles.
Input is strongly recommended for Checking, Simulation, and Thermosiphon
calculations.
Remember that the number of baffles is one greater than the number of
Baffle Spaces.
This item is not needed for unbaffled or rod-baffled exchangers. If you set the
number of baffles to zero, the exchanger will be assumed to be unbaffled,
even if you have not specified this under baffle type.
If you omit this item, then the program will attempt to determine a sensible
number of baffles, based on tube length, baffle spacing, and other dimensions.
A warning message will be given.
Note:
Front Head End Length + Rear Head End Length + Baffle Spacing x (Number
of Baffles - 1) = Tube Length. The program will check this and make
corrections if necessary.

If up-and-over flow has been specified for an E-shell with single segmental,
then there must be an even number of baffles if the shell side nozzles are on
opposite sides of the shell, or an odd number if they are on the same side. If
your input is not consistent with this, the program will adjust the number of
baffles.
For I, J and G shells, it is assumed that there is always a central baffle. The
number required is the total number of baffles in both shell side passes
including this central baffle.

As the Bundle Geometry varies with unit type, refer to the following sections
for detailed diagrams of each combination:
U-Tube
Fixed Tubesheet
Floating Head

Note the following special cases:

`F' Shell Type
`G' Shell Type
`H' Shell Type
`I' Shell Type
`J' Shell Type
 Shell&Tube Baffles - Type
Single Segmental
Double Segmental
Unbaffled
Rod
Segmental baffles are the most common type of baffle, with the single
segmental baffle being the type used in a majority of shell and tube heat
exchangers. The single segmental baffle gives the highest shell film coefficient
but also the highest pressure drop. A double segmental baffle at the same
baffle spacing will reduce the pressure drop dramatically (usually somewhere
between 50% - 75%) but at the cost of a lower film coefficient. The baffles
should have at least one row of overlap and therefore become practical for a
20 mm or 0.75 in. tube in shell diameters of 305 mm (12 in.) or greater for
double segmental and 610 (24 in.)
Rod Baffle design is based on the construction and correlations developed by
Phillips Petroleum. Rod baffles are limited to a square tube pattern. The rods
are usually about 6 mm (0.25 in.) in diameter. The rods are placed between
every other tube row and welded to a circular ring. There are four repeating
sets where each baffle is rotated 90 degrees from the previous baffle.
The default is single segmental for all cases except K shells, X shells and D-
type shells (double pipes), which are assumed to be unbaffled.
Rod baffles are not supported for M-type shells (multi-tube hairpin units).
 Shell&Tube Baffles - Tubes in Window
Tubes in window means that some tubes do not pass through every
Transverse Baffle. These tubes may be susceptible to a vibration problem as
they will have a longer unsupported length than the other tubes in the bundle
that pass through every Transverse Baffle.
No Tubes in window means that every tube passes through every
transverse baffle as in the following figure:
 Shell&Tube Baffles - Orientation
Horizontal
Vertical
Select whether the baffle cut is horizontal or vertical. Vertical exchangers
should be viewed as horizontal, with the shell side inlet nozzle at the top.
Vertical cut of the baffles, i.e. side-to-side flow, or
Horizontal cut of the baffles, i.e. up-and-over flow
For single phase exchangers, up and over flow (horizontal cut baffles) is best
practice if the shell side nozzles are at the top or bottom of the shell. This
avoids the region under the nozzle with tubes removed providing a large area
in which flow could bypass the bundle. Large bypass areas give reduced
bundle mass flux, and hence reduced shell side coefficients for single phase
flows.
For boiling or condensing shell side flows, potential phase separation problems
with up and over flows (particularly for condensing) means vertical baffle cuts
are preferred. Boiling and condensing coefficients usually depend less on
bundle mass flux than single phase coefficients.
Shell&Tube Baffles - Cut (%d)
 Shell&Tube: Number of Plugged Tubes
The number of plugged (blocked off) tubes is subtracted from the total
number of tubes to give the number of thermal tubes, used for tube side heat
transfer and pressure drop calculations.
If you have specified a total number of tubes in the bundle, then this number
is allocated among the passes, uniformly in order of pass region number. The
default is unlikely to be correct, so you should amend it – particularly if the
number of plugged tubes is more than one or two percent of the total number
in the pass.

See also:
Pass Details
Plugged Tubes
 Shell&Tube Location of Front Head for Vertical
Units
For exchangers that are vertically mounted, the Front Head can either be
located at the top or at the bottom of the exchanger.
 Shell&Tube "E" shell flow direction (inlet nozzle
location)
For ‘E’ Shell Types, the Shell Side Inlet Nozzle can either be located at the
Front Head end or the Rear Head end of the Shell Cylinder.
 Shell&Tube: Double Pipe or Hairpin Unit Shell
Pitch
This input is the pitch between shell center lines. It is used to define the U-
bend radii in multi-tube hairpin units and in double pipe units with U-bends.
 Shell&Tube: Tube Side Inlet at Front Head
Tube side flow normally enters at the front (fixed) head of an exchanger. This
option is only available when there is a possibility that the tube side flow may
enter at the rear head. This applies only to single pass exchangers. In some
vertical single pass exchangers, the option is not available, because there is
effectively only one option; for example, in tube side reflux, entry must be at
the lower end of the exchanger. The option is also not available with multiple
single-tubepass E-shells where the tube side inlet end is defined by the
requirement for either overall counterflow or overall co-current flow.
When the option is available, you can specify entry at either the fixed (front)
or rear head. In multi-shell exchangers, the specification refers to the overall
tube side inlet.

See also:
Overall flow for multiple shells
Location of front head in vertical units
 Shell&Tube: Flow within Multi-tube Hairpin (M-
shell)
You can specify that the overall flow within a multi-tube hairpin unit (M-shell)
is either co-current or counter-current.
The option is also available for two double-pipe units (D-shells) connected by
U tube.

See also:
Overall Flow for Multiple Shells
 Shell&Tube: Overall Flow for Multiple Shells
Since multiple shells in series are usually needed due to temperature range
overlap of the streams, an overall Counterflow is the only
thermodynamically possible option.
If no temperature range overlap exists, you can sometimes benefit by
modelling the flow of one side to be in a series (to achieve good heat transfer)
and the other side to be in parallel (to achieve a low pressure drop); to model
these flows, use the options Shell side in parallel, tube side in series or
Tube side in parallel, shell side in series.
You might also benefit by using overall co-current flow, which gives a large
temperature difference at inlet, and a small one at outlet, by using the Co-
current option.
Note: Only use options other than Counterflow if the hot and cold stream
temperature ranges do not overlap.
When there are N shells in series, shell 1 always has the shell side inlet. The
tube side stream enters in shell N when there is overall counterflow. In other
flow configurations, the tube side stream enters in shell 1.
If in addition to N shells in series, it is specified that there are M shells in
parallel, then M refers to the series flow stream(s). If it is specified that one
side is connected in parallel, then overall there are M times N parallel flows of
this stream.
This input is not needed with a single multi-tube hairpin unit. There is a
separate input for co- or countercurrent flow within such units. With multiple
multi-tube hairpin units in series, both inputs are available.

See also:
Flow with a Multi-tube Hairpin unit
Tube side Inlet at Front Head
 Shell&Tube Shell(s) - Thickness
Enter the Thickness of the Shell Cylinder.
If this input is left blank, then the program will calculate a value.
If the Shell Outside Diameter has been input then the Shell Inside Diameter
will be calculated by using the Shell Thickness.
Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Front Head - ID
Enter the Inside Diameter of the Front Head.
If this value is not input, then it will be set to equal the Shell Inside Diameter.
Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Front Head - Thickness
Enter the Thickness of the Front Head Cylinder.
If this input is left blank, then the program will calculate a value.
If the Front Head Outside Diameter has been input then the Front Head Inside
Diameter will be calculated by using the Front Head Thickness.
Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Rear Head - ID
Enter the Inside Diameter of the Rear Head.
If this value is not input, then it will be set to equal the Shell Inside Diameter.
Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Rear Head - Thickness
Enter the Thickness of the Rear Head Cylinder.
If this input is left blank, then the program will calculate a value.
If the Rear Head Outside Diameter has been input, then the Rear Head Inside
Diameter will be calculated by using the Rear Head Thickness.
Note: This input will not be available when the Calculation Mode is set to
Design.
 Shell&Tube Kettle - ID
Enter the Inside Diameter of the Kettle Cylinder.
If the Kettle Cylinder is to be made from Pipe, it is recommended to leave this
input blank, and enter a value for the Kettle Outside Diameter.
Note: This input will not be available when the Calculation Mode is set to
Design and Shell Type is not set to K – Kettle.
 Shell&Tube Kettle - OD
Enter the Outside Diameter of the Kettle Cylinder.
If the Kettle Cylinder is to be made from Plate, it is recommended to leave
this input blank, and enter a value for the Kettle Inside Diameter.
Note: This input will not be available when the Calculation Mode is set to
Design and Shell Type is not set to K – Kettle.
 Shell&Tube Front Cover Type
The front cover type appears only when you specify a B type front head. A flat
bolted cover is assumed for the other front head types.
This is included for the accuracy of the cost estimate and a more complete
heat exchanger specification. The default is ellipsoidal.
 Shell&Tube Front Cover Welded to a Cylinder
The cover welded to a cylinder option determines if there is a cylinder
between the front head flange (or tubesheet in the case of a hemispherical
cover) and the attached cover.
This is included for the accuracy of the cost estimate and a more complete
heat exchanger specification. The default is yes, except when the cover is
hemispherical.
 Shell&Tube Rear Cover Type
The rear cover type is based on the selected rear head type. The flat bolted
cover is for L, N, P and W type rear heads. The flat welded and form covers
(except for the dished cover) are available on the M type rear heads. The
dished and ellipsoidal is available on the S and T rear heads.
This is included for accuracy of the cost estimate and a more complete heat
exchanger specification. The defaults are: flat bolted for L, N, P, or W types;
ellipsoidal for M type; dished for S or T type.
 Shell&Tube Rear Cover welded to a Cylinder
The cover welded to a cylinder option only applies to M type rear heads. For
other cases it is ignored. It determines if there is a cylinder between the rear
head flange (or tubesheet in the case of a hemispherical cover) and the
attached cover.
This is included for the accuracy of the cost estimate and a more complete
heat exchanger specification. The default is yes, except when the cover is
hemispherical.
 Shell&Tube Shell Cover Type
A shell cover type should be specified for a U-tube, S, or T type rear head
exchangers. Shell cover may be welded directly to shell cylinder or bolted to
the shell cylinder with a pair of mating body flanges. The default is Ellipsoidal
for U-tube, S, T type rear heads.
 Shell&Tube Distance from U-bend centre to
shell cover
Enter the distance from the end of the straight tube length along the
longitudinal axis of the shell to the inside surface of the shell cover.
 Shell&Tube Front Tubesheet Thickness
Enter the Thickness of the Front Tubesheets.
If this input is left blank, then the program will calculate a value.
The program uses the tubesheet thickness to determine the effective tube
length for effective surface area calculations.
 Shell&Tube Rear Tubesheet Thickness
Enter the Thickness of the Rear Tubesheets.
If this input is left blank, then the program will calculate a value.
The program uses the tubesheet thickness to determine the effective tube
length for effective surface area calculations.
 Shell&Tube Tube Projection from Front
Tubesheet
Enter the distance that the tubes protrude beyond the face of the tubesheet.
If a tube ends flush with the tubesheet surface, the projection is zero. Two
separate projections can be defined, one at the Front Head, the other at the
Rear Head. A typical value might be 3mm or 1/8 inch.
 Shell&Tube Tube Projection from Rear
Tubesheet
Enter the distance that the tubes protrude beyond the face of the tubesheet.
If a tube ends flush with the tubesheet surface, the projection is zero. Two
separate projections can be defined, one at the Front Head, the other at the
Rear Head. A typical value might be 3mm or 1/8 inch.
 Shell&Tube Include Expansion Joint
This input only applies to fixed tubesheet exchangers. It does not affect the
thermal calculations, but if an expansion joint is required, it can have a
significant affect on the cost.
As part of the thermal calculations, an estimate of the differential expansion
between the shell and the tubes is made. An expansion joint may then be
included based on this estimate and the setting of this input.
 Shell&Tube Flange Type - Hot Side
The Flange Type – Hot Side refers to the Body Flanges that are attached to
the designated Hot Side of the shell and tube heat exchanger. This item can
have a significant effect on the cost.
 Shell&Tube Flange Type - Cold Side
The Flange Type – Cold Side refers to the Body Flanges that are attached to
the designated Cold Side of the shell and tube heat exchanger. This item can
have a significant effect on the cost.
 Shell&Tube Lowfin Tube Databank
The databank lists tubes from a number of vendors.
To select a tube, click a row and it will become highlighted.
Click OK and the data will be written back to the Low Fins input screen.
 Shell&Tube Fin Density
If you have not selected a tube from the Lowfin Databank enter the Fin
Density.

[Input item 111.3]

 Shell&Tube Tube Wall Thickness under Fin
If you have not selected a tube from the Lowfin Databank enter the Tube Wall
Thickness under Fin. If omitted, the default is 1.5mm / 0.058 in.

[Input item 111.2]

 Shell&Tube Tube Root Diameter
If you have not selected a tube from the Lowfin Databank enter the Tube Root
Diameter. If omitted, the default is 1.53mm / 0.014 in.

[Input item 111.1]

 Shell&Tube Fin Height
If you have not selected a tube from the Lowfin Databank enter the Fin
Height. If omitted, the default is 1.53mm / 0.06 in.

[Input item 111.4]

 Shell&Tube Fin Thickness
If you have not selected a tube from the Lowfin Databank enter the Fin
Height. If omitted, the default is 0.35mm / 0.014 in.

[Input item 111.5]

 Shell&Tube Outside/Inside Surface Area Ratio
The ratio of the total finned and unfinned heat transfer surface area on the
outside of the tube divided by the inside heat transfer surface area of the
tube per unit length.
 Shell&Tube Lowfin Manufacturer
If required for output purposes, enter the name of the lowfin tube
manufacturer.
 Shell&Tube Lowfin Catalogue Number
If required for output purposes, enter the catalogue number of the lowfin
tube.
 Shell&Tube Distance Unfinned at Baffle
For lowfin tubing, enter the length of unfinned tubing at a baffle as show
below.

If the baffle pitch is less than 305mm (12in) it is assumed that the tube is
finned over its whole length, and any value entered here will be ignored.

[Input item 111.6, default = 0.0]

 Shell&Tube Longitudinal Fins per Tube
Enter the number of longitudinal fins on each tube.
A value must be supplied in Checking and Simulation modes; in Design mode,
a default will be calculated.

[Input item 171.1]

 Shell&Tube Longitudinal Fin Height
Enter the height of the fins on a longitudinally finned tube. Ensure that the
tube pitch specified allows for this fin height.
A value of fin height must be supplied in Checking and Simulation modes; in
Design mode, a default will be calculated.

[Input item 171.2]

 Shell&Tube Longitudinal Fin Thickness
Enter the longitudinal fin thickness.
The default is 0.89 mm (0.035 in).

[Input item 171.2]

 Shell&Tube Longitudinal Root Spacing
Enter the space between a pair of adjacent fins at the fin root.
This item allow for longitudinally finned tubes made using U-shaped channels
to form a pairs of fins, with the flat bottom of each U being attached to the
tube. Using the default value will usually have minimal affect on the results.
The default is 3 times the fin thickness.

[Input item 171.3]

 Shell&Tube Longitudinal Fin Cut and Twist
Length
Enter the distance between successive radial cuts on each longitudinal fin.
The default is no cut-and-twist.

[Input item 171.5]

 Shell&Tube Tube Insert Type
None
Twisted Tape
KHT Twisted Tape
KHT Plain Core
KHT Helicore
KHT Wire Wrapped Core
hiTRAN-Wire Loop

The option for a twisted tape is available within the program. All the other
options are available only if you have been supplied with special software (in
the form of dlls) by the insert manufacturers.
The KHT options are from Koch Heat Transfer (previously Brown Fin Tube).
The dll is the same as that for KHT twisted tubes, but you will need to check
that your version is enabled for tube inserts as well.
HiTRAN wire loop inserts are manufactured by Cal Gavin, who distribute and
license the dll for these inserts.
 Shell&Tube Twisted Tape 360 degree Twist
Pitch
This item is used for twisted tapes (basic version) or KHT twisted tapes.
Enter the distance between each 360 degree twist of a twisted tape insert.
 Shell&Tube Twisted Tape Thickness
This item is used for twisted tapes (basic version) or KHT twisted tapes.
Enter the thickness of the twisted tape inserts.
 Shell&Tube Tube Insert Core Outside Diameter
This item is used for KHT inserts, where the insert is in the form of a smaller
tube (core) inserted in each tube, to reduce the flow area, hence increasing
the tube side mass flux and heat transfer coefficient. Enter the diameter of
this core.
 Shell&Tube Tube Insert Wire Outside Diameter
This item is used for KHT inserts, where the insert is in the form of a smaller
tube (core) inserted in each tube. A thin wire wrapped spirally around the
core supports it from the main tube, giving a high tube side mass flux and
heat transfer coefficient. Enter the diameter of this wire, which wraps the
tubular core.
 Shell&Tube hiTRAN Insert Calculation Type
Select the hiTRAN calculation mode from the options given below.
· Use Previous Insert
· Find Optimum Insert
· Specify New Insert
All hiTRAN calculation options require the installation of the hiTRAN wire
mesh calculation library (supplied and licensed solely by Cal Gavin Limited)
which calculates single phase tube-side heat transfer coefficients and
frictional pressure drops, and helps perform insert selection.
Find Optimum Insert
Determine (in checking/rating mode) the hiTRAN wire insert (identified by a
50 character string) which gives the maximum tube-side heat transfer
coefficient while ensuring the tube-side pressure drop is less than the
specified maximum tube-side pressure drop. It is assumed that the calculated
hiTRAN wire insert is present in all straight sections of tubes.
Use Previous Insert
Specify that a hiTRAN wire insert, previously determined using “Find
Optimum Insert”, is present in all straight tube sections in a Shell&Tube
calculation (all modes).
Specify New Insert
Specify a hiTRAN wire insert (identified by a 50 character string) is present in
all straight tube sections in a Shell&Tube calculation (all modes).

Note:
Calculations with hiTRAN can be performed for boiling or condensing streams,
as well as single phase streams, but the results should be treated with
caution.
It is assumed that the calculated hiTRAN wire insert is present in all straight
sections of tubes. These Inserts are not used within U-bends. This is allowed
for explicitly with Advanced Method calculations, but only approximately with
the Standard Method.
 Shell&Tube hiTRAN Part No.
This 50 character string uniquely identifies a hiTRAN wire insert type
available from Cal Gavin Limited. The best insert for a given application can
be determined using the Find Optimum Insert mode (jump to or alternatively
the user can specify the part number.
See also:
hiTRAN Insert Calculation Type
 Shell&Tube hiTRAN Part No. (previous)
Previously specified or calculated hiTRAN wire insert part number. The 50
character string uniquely identifies a hiTRAN wire insert type available from
Cal Gavin Limited. The best insert for a given application can be determined
using the Find Optimum Insert mode or alternatively the user can specify the
part number.
See also:
hiTRAN Insert Calculation Type
 Shell&Tube Twisted Tube twist pitch
Enter the distance between each 360 degree twist of the twisted tube.
 Shell&Tube Shell Type: within Shroud (convert
to)
A shroud is a metal jacket that wraps around the outside of the tube bundle
inside the shell of a shell and tube heat exchanger. By appropriately
positioning of gaps cut out of the shroud, the shell side fluid can be made to
take a path that it would take in a different shell and tube heat exchanger
type. For example, suppose an E-shell has the shell side inlet nozzle at the
top of the front head end of the unit, and a shroud with two gaps cut out of
the shroud near the front head end, with a longitudinal flow baffle placed to
divide the tube bundle. The shell side fluid enters the tube bundle through
inlet gap in the shroud flows along the top half of the tube bundle, turns
around and flows back along the bottom of the tube bundle towards the front
head end of the unit. The shell side fluid then exits through the outlet gap in
the shroud and runs along the clearance space between the outside of the
shroud and the inside of the shell to the shell side outlet nozzle at the rear
head end. The shell side fluid would have made just one pass if the E-shell did
not have a shroud, but the presence of the shroud and the placing of the gaps
has made it take the path over the tube bundle that it would take in an F-
shell with no shroud. Thus, if you specify that the exchanger has a shroud,
you must select the effective shell type that the shroud converts the unit to.
Note that K-shells may not have shrouds, and that Shell&Tube does not
presently allow the modeling of X-shells with twisted tubes.
 Shell&Tube Shell Type: Nozzle Layout (convert
from)
Select the shell type that represents the required arrangement of nozzles
within the shell assembly.
 Shell&Tube Shroud Inlet Location
The location of the shroud inlet gap or gaps can convert a shell type from an
E to an F for example.
 Shell&Tube Shroud Inlet Gap Length
The length of gap in the shroud where the shell side fluid enters the bundle.
 Shell&Tube Shroud Outlet Gap Length
The length of gap in the shroud where the shell side fluid exits the bundle.
 Shell&Tube Shroud Thickness
The thickness of the shroud metal that surrounds the bundle.
 Shell&Tube Skid Bar Angle (degrees)
Two skid bars are used to hold the shroud and the bundle into place. Skid
bars run parallel to the tubes and for some bundles act as a channel for fluid
to flow through. Increasing or decreasing this Angle may restrict or increase
channel flow area. 60 degrees is the default.
 Shell&Tube: Tube Internal Enhancement
When the option Internal enhancement is set for the Tube Type, this item
lets you choose from a selection of commercially produced tubes with internal
enhancements.
The current options for internal enhancement are all Wolverine tubes with
internal enhancements designed for high Reynolds number single phase flows.
These tubes also have external enhancements, designed for boiling or
condensing applications. The program does not explicitly model the external
enhancement, but you can make allowance for it by explicitly specifying the
shellside heat transfer coefficient or by specifying a multiplier for the
calculated coefficient.
A wide range of tube geometries are available, and datasheets are available
via the internet, giving both key geometric parameters and the formulae for
calculating the internal heat transfer coefficient and pressure gradient.
Inputs for the tube outer diameter and wall thickness are repeated on the
Internal enhancements tab to allow you to match what is on the
manufacturer’s datasheet.
If you select the option Wolverine Turbo: any, then four extra input items
are required. All appear on the Manufacturer’s data sheet. They are
· Internal surface area per unit length
· Sieder-Tate coefficient: STC
· Coefficient for Darcy fiction factor: C
· Exponent for Darcy fiction factor: D
Ideally, the outside diameter minus twice the wall thickness should be equal
to the nominal inside diameter as specified on the Manufacturers data sheet.
Some compromise might be needed in selecting the wall thickness, since it
might need to allow for the effect of variation due to both internal and
external enhancements.
If you select any of the other enhancement types, the four extra items above
are not used. The program will look at the specified tube diameter and wall
thickness and try to identify an appropriate, matching tube geometry from a
limited subset of those that are now available. The wall thickness should in
this case be the “plain end” value. The program uses internally stored
datasheet values of the internal area, of the STC, C and D parameters, and of
the nominal inside diameter. Many more tube geometries are now available
than the subset for which the program has internally stored values, and not
all can be identified correctly given just the tube size and wall thickness, so
use of the Wolverine turbo: any option may be preferable.
 Shell&Tube Baffle Cut (% diameter)
inner/outer/intermediate
This value is the amount of the Transverse Baffle that is cut away expressed
as a percentage of the Shell Inside Diameter.

The baffle cut range depends on the baffle type:

Single Segmental Baffles
Double Segmental Baffles
Triple Segmental Baffles

If not input, this item is estimated on the basis that the superficial area
(ignoring tubes) between the inner cuts of the cap-shaped baffles is the same
as the sum of the two cut areas either side of the band-shaped central baffle.
If necessary, the input value of the baffle cut is adjusted slightly so as to be
sensibly positioned relative to tube locations that pass through the baffle.
 Shell&Tube Align Baffle Cut with Tubes
Set default
Yes
No

Selecting Yes will result in the program adjusting the baffle cut % so that the
baffle cut either passes through the centerline of a line of tubes or in through
the centerline between two lines of tubes.
Selecting No will result in the program using the value entered for the baffle
cut %.
 Shell&Tube Multi-Segmental Baffle starting
Baffle
One piece
Two piece

This applies to Double Segmental baffles only.

 Shell&Tube Baffle Cut Orientation
Horizontal
Vertical

Select whether the baffle cut is horizontal or vertical. Vertical exchangers

should be viewed as horizontal, with the shell side inlet nozzle at the top.
Vertical cut of the baffles, i.e. side-to-side flow, or
Horizontal cut of the baffles, i.e. up-and-over flow
For single phase exchangers, up and over flow (horizontal cut baffles) is best
practice if the shell side nozzles are at the top or bottom of the shell. This
avoids the region under the nozzle with tubes removed providing a large area
in which flow could bypass the bundle. Large bypass areas give reduced
bundle mass flux, and hence reduced shell side coefficients for single phase
flows.
For boiling or condensing shell side flows, potential phase separation problems
with up and over flows (particularly for condensing) means vertical baffle cuts
are preferred. Boiling and condensing coefficients usually depend less on
bundle mass flux than single phase coefficients.
 Shell&Tube Baffle Thickness
Enter the Transverse Baffle thickness.
The default will be according to the recommendations of TEMA.
 Shell&Tube Distance between baffles at central
inlet/outlet for G, H, I, J shells
Enter the length of the nozzle region.
The distance is measured between the centers of the two baffles adjacent to
the nozzle.
BJU Bundle:

BGU Bundle:

BHU Bundle:
 Shell&Tube Distance between Baffles at Center
of H shell
Enter the length of the central region in an H-shell, in which there is flow
between the upper and lower part of the shell.
The distance is measured between the centers of the two extreme flow baffles
that bound this region.
The central length approximates to the distance between the two halves of
the longitudinal baffle in an H-shell, since the extreme flow baffles will be
located at the ends of the longitudinal baffle. In an unbaffled exchanger,
enter the length between the two halves of the longitudinal baffle.
There is assumed to be a support baffle in the middle of this central region,
but this does not need to be specified explicitly.
If omitted this item is usually estimated to be double the mean length of the
endspaces at the ends of the exchanger.
BHU Bundle
 Shell&Tube Baffle OD to Shell ID diametric
clearance
Enter the diametral clearance between the baffles and the shell wall. This is
the difference between the outside diameter of the baffles, and the inside
diameter of the shell.
To obtain a zero clearance, enter 0.
The default clearance is according to TEMA.
 Shell&Tube Baffle Tube Hole to Tube OD
diametric clearance
Enter the diametral clearance between the tube and the baffle hole. This is
the difference between the outside diameter of the tubes, and the inside
diameter of the holes in the baffles through which they pass.
To obtain a zero clearance, enter 0.
The default clearance is according to TEMA.
 Shell&Tube Special Inlet Nozzle Support
Specify if there is a special support at the inlet nozzle. This item provides
additional support to the tubes nearest to the inlet nozzle. It only affects
Vibration: Natural Frequency.
This is a special support applied only to the first tube row after the inlet
nozzle (sometimes referred to as the 'top' tube row of Vibration: Tube Rows
Examined). Unlike Intermediate Supports, this support can be applied for
either Tubes in Window or no Tubes in Window bundles. Similar to
intermediate supports, it is assumed that the support does not affect fluid
flow.
You should enter a sensible Distance to Shell Side Nozzle (at inlet) to locate
the support. Remember for some exchangers, the inlet nozzle may be furthest
from the front head.
The support is positioned along the first tube row after the inlet nozzle, on
the center-line of the nozzle. It is common to have the support attached to an
Impingement Plate.
From Vibration: Entry conditions, this location can suffer from specific
vibration problems. This item may help to reduce or remove vibration
problems in the inlet area.

Please note:
This item is only relevant for Vibration.
This item is ignored if you apply any Intermediate Supports (which usually
apply across the tube bundle, not just the first tube row).
This item is not relevant to J-shell, since there is a central baffle present
beneath the nozzle already.
For X-shell (and K-shell), it is recommended that normal Intermediate
Supports are applied.
 Shell&Tube Support or Blanking Baffle at Rear
End
Set default
Yes (normal)
No
Yes (Rigid)

Specify if there is a support/blanking baffle at the rear end head. The default
is that they are present with S type and T type rear end heads, where they
are a TEMA requirement, but are otherwise assumed to be absent unless you
specify that they are present.
Support/blanking baffles are sometimes used with U-tube bundles. In
principle you can specify one with any rear end head type, though they are
only normally used with pull through heads.
When there is a support/blanking baffle, you should also specify the tube
length beyond this baffle. This identifies a length of tube which is ineffectual
for heat transfer purposes.
The type of support presented by the support/blanking baffle can be
controlled. The support can act like a normal flow baffle (sometimes called a
pinned support, hinge, or knife-edge). Alternatively the support can act like a
tubesheet (rigid support, or clamped). Essentially the support is judged on
how much tube rotation is allowed at the baffle.
It is common to assume a normal (pinned) support but, if you have a thick
support/blanking baffle that minimizes tube rotation, you may consider
selecting a rigid support. The type of support only affects the tube Vibration:
Natural Frequency.
If you select a rigid support/blanking baffle for a U-tube bundle then the U-
bend is effectively excluded from the Shell&Tube vibration calculations. U-
bend Heat Transfer is appropriately handled.

See also:
Shell and Tube Geometry - Bundle Geometry
 Shell&Tube Support/Baffle to tangent of U-
bend distance
Enter the distance from the centre of the support/baffle to the tangent line of
the U-Bend.

See also:
Shell and Tube Geometry - Bundle Geometry
 Shell&Tube Number of Extra Supports for U-
bends
Enter the number of special supports on the U-bend. These are assumed to be
equally spaced around the U-bend. They are important for vibration
calculations, but are not assumed to contribute significant extra shell side
pressure loss.
 Shell&Tube Number of Supports at center of H
shell
Enter the number of Supports to be fitted at the center of the H shell.
 Shell&Tube Number of Supports at Inlet/Outlet
for G, H, I, J Shells
Enter the number of Supports at the Shell Side Inlet or Outlet Nozzles.
 Shell&Tube Number of Supports at K, X Shells
Enter the number of Supports within a K or X Shell.
 Shell&Tube Number of Supports between
Central Baffles
The input only applies where No Tubes in the Window construction is used.
Enter the number of Supports between the central Baffles.
 Shell&Tube Number of Supports at Front Head
End Space
The input only applies where No Tubes in the Window construction is used.
Enter the number of Supports within the Front Head End Space.
 Shell&Tube Number of Supports at Rear Head
End Space
The input only applies where No Tubes in the Window construction is used.
Enter the number of Supports within the Rear Head End Space.
 Shell&Tube Window Length at Rear Head for F,
G, H Shells
Enter the distance between the end of the Longitudinal Baffle and the end of
the Shell at the Rear Head.
 Shell&Tube Window Length at Front Head for G,
H Shells
Enter the distance from the Shell Side face of the Front Head Tubesheet to
the start of the Longitudinal Baffle.
 Shell&Tube Window Length at Center for H
Shells
Enter the distance at the centre of the H shell between the two Longitudinal
Baffles.
 Shell&Tube Longitudinal Baffle Thickness
Enter the Longitudinal Baffle thickness.
The default will be according to the recommendations of TEMA.
 Shell&Tube: Longitudinal Baffle to Bundle
Clearance
You can specify the clearance between the surface of the longitudinal baffle,
in an F, G, or H-shell, and the surface of the adjacent tubes.
 Shell&Tube Number of Regions for Variable
Baffle Pitch
Variable baffle pitch in Shell&Tube can be defined by specifying up to four
regions along the exchanger, each of which has a different baffle
pitch(spacing) , and optionally a different baffle cut.
The default value of "One baffle region" applies to the standard case when the
same baffle spacing and cut apply throughout the exchange. For variable
baffle pitch, you must specify, two, three or four regions.
The end spaces of an exchanger do not count as baffle regions. End spaces
are present in exactly the same way for both a normal exchanger and one
with varying baffle pitch.
You should then specify the baffle spacing, and number baffle spaces in each
region. The regions are defined so region one is next to the shell side inlet,
and the highest numbered region is next to the shell side outlet.
The exception is Design mode, where you can specify a number of baffle
regions, but need not supply any information about baffle spacing or number
of spaces. The program will select these, based on the normal baffle pitch
search algorithm, but making use of the parameter in Program Options /
Design Options Ratio "first to last pitch ratio" to select the various sizes.
For a simple E shell, the sum of the number of baffle spaces in all the regions
is one less than the number of baffles. In other cases the relationship is more
complex.
When there is split shell side flow, you specify the number of baffle spaces for
one shell side flow path. Other flow paths are assumed to be symmetric.
For F, G and H-shells, where a longitudinal baffle splits the shell into two
halves, then if you specify two regions, one is assumed to apply to the inlet
half, the other to the outlet half. The lengths of the two regions (number of
baffles times the baffles pacing) must be the same in both halves. You can
also specify four regions, with two in one half and two in the other half, again
with the constraint that the total baffled region in the two halves is the same.
Three regions is not allowed for these shell types, but you can always make
four by splitting one region into two with the same spacing.
See also
General advice on Variable Baffle Pitches
 Shell&Tube Number of Baffle Spaces
This item is needed when the variable baffle pitch option is used. Each baffle
region has a different baffle spacing, and the number of baffle spaces in each
region must be specified.
 Shell&Tube Baffle Cut Percent, Outer
Enter the baffle cut, as a percentage of the shell diameter for each of the
baffle regions defining the variable baffle pitch. Generally regions with large
baffle spaces will have large baffle cuts, but there is no requirement to do
this.
If you have entered a baffle cut on the main input page, then this value will
be used as a default for all the baffle regions.
For "no tubes in window" designs, the baffle cut must be the same in all the
baffle regions.
Any cut you input is treated as a nominal cut. The cut location is adjusted to
match the exact location of the tube lines, and this slightly different value is
used in the calculations
Single segmental baffles have only one cut, the outer cut. Double segmental
baffles have two cuts, and this is the outer one, found each side of the one-
piece baffle.
Triple segmental baffles cannot be used with variable baffle pitch.
See also
General advice on Variable Baffle Pitches
 Shell&Tube Baffle Cut Percent, Inner
If you have Double segmental baffles, enter the inner baffle cut, as a
percentage of the shell diameter for each of the baffle regions defining the
variable baffle pitch.
There are two possible ways of defining an inner baffle cut. The one required
here is the distance from the centre of the shell to the baffle edge, as a
percent of the shell diameter. This is half of the alternative definition, using
the baffle edge to baffle edge distance for the two-piece baffle.
If you have entered a baffle cut on the main input page, then this value will
be used as a default for all the baffle regions.
If you do not enter any value for the inner cut, it will be evaluated within the
calculation, so that its flow area matches that of the outer cut.
See also
General advice on Variable Baffle Pitches
 Shell&Tube General advice on Variable Baffle
Pitches
Variable baffle pitch can be useful when there are conflicting demands on the
choice of baffle pitch. For some parts of the duty a wide pitch is required to
give an acceptable pressure drop, while in other parts a tighter pitch is
needed to keep the heat transfer coefficient up to a reasonable value.
An example might be a condensing multi-component mixture, where a
relatively wide initial pitch will reduce the pressure drop, but have a smaller
effect on the high initial heat transfer. As condensation proceeds and the
volume of gas reduces, pressure drop becomes less important, but a reduced
baffle pitch can have the benefit of increasing the otherwise poor heat
transfer. Another example could be condensation followed by significant
subcooling, where the condensing and subcooling regions inherently need
different baffle pitches.
Very often much can be achieved with just two baffle pitch regions, but taking
care to get the appropriate pitch and number of spaces in each region.
Remember also that end spaces can have a significant effect on performance.
Even without variable baffle pitch, benefits can be obtained by increasing or
decreasing the baffle pitch marginally, to change the size of the end spaces.
Even just moving all the baffles along the exchanger, to increase one end
space and decrease the other can have benefits.
Design mode with variable baffle pitches can help indicate whether their use
is beneficial, but uses some simplifying assumptions. You may be able to
make further improvements, or convert a "near" design into an acceptable
one, by creating a checking case and manually adjusting the size and number
of pitches in each region.
Guidance on the effects of a particular baffle pitch variation, and insight as to
where improvements can be made can be obtained by using graphs of shell
side pressure and shell side heat transfer coefficient along the exchanger. On
the View menu, select Preset Plots, and select these two graphs under "Shell
side performance". The regions of the exchanger with the largest pressure
gradient, and the lowest coefficient will be clear, and one or both of these can
be targeted for improvement.
Return to:
Variable Baffle Pitch
 Shell&Tube Number of Deresonating Baffles
Enter the number of Deresonating Baffles to be used within the tube bundle.

See also:
Deresonating Baffles
 Shell&Tube Largest Deresonating Baffle-Baffle
or Baffle-Shell Distance
Enter the largest clearance between Deresonating Baffles or between the
Deresonating Baffle and the Shell.

See also:
Deresonating Baffles
 Shell&Tube Main input/Tube Layout
inconsistencies
Default (use layout)
Treat as Fatal Error
Use Layout Value (warning)
Use Main Input value (warning)

This input allows you to determine what action is taken if there is a conflict
between an existing tube layout and data on the input screens.
It will only be applicable if the Tube Layout Option is set to Use Existing
Layout.
See also
Tube Layout: Overview
 Shell&Tube: Bundle Limit Symmetry
The tube bundle is limited by the open spaces, if any, on each of the four
sides of the bundle (top and bottom, left and right). In a normal bundle, the
size of the open spaces is related to nozzle size and is different for inlet and
outlet nozzles. This often leads to asymmetric bundle limits.
You can impose a requirement that the bundle limits are symmetric. The
benefit of symmetric bundle limits is that all baffles with cuts parallel to these
limits have the same pattern of holes. The downside is that, in some cases, a
significant number of tubes might be lost in achieving this symmetry.
If you elect to impose symmetric bundle limits, the basic tube layout
symmetry will default to full symmetry.
See also
Tube Layout: Overview
 Shell&Tube Number of Sealing Strip Pairs
Enter the number of pairs of sealing strips.
See also
Tube Layout: Overview
 Shell&Tube: Sealing Strip Orientation
You can select whether sealing strips are transverse to the flow that is
parallel to the baffle cut, or radial.
It is also possible to edit sealing strips on the tube layout diagram, if you
select Use Existing Layout. This permits the angle of each sealing strip to be
changed individually.
 Shell&Tube Open distance at Top of Layout
The distance from the edge of the top row of tubes to the inside diameter of
the shell cylinder can be specified.

The open distance at the bottom of the layout and on the left and right had
sides of the layout are defined similarly and can also be specified in the input
if required. Values must be larger than the circumferential shell to bundle
distance (defining the outer tube limit). Smaller values will be ignored.
Normally these inputs are optional, and should in most cases be omitted. No
defaults are shown, but values are calculated based on removing tubes under
nozzles, where appropriate, and on fitting an exact number of rows and
columns of tubes, together with pass partition lanes as appropriate.
You can however use one or more of these inputs to exactly specify open
distances, overriding other considerations. If you specify both top and bottom,
or both left and right hand sides, and your values do not correspond to an
integral number of tubes rows or columns, then your inputs will be amended.
See also:
Tube Layout: Overview
Open Distances with Pass Details Specification
 Shell&Tube Open distance at Bottom of Layout
The distance from the edge of the bottom row of tubes to the inside diameter
of the shell cylinder can be specified.
See also:
Tube Layout: Overview
Open Distance at Top of Bundle
Open Distances with Pass Details Specification
 Shell&Tube Open distance on Left Side of
Layout
The distance from the edge of the left-hand column of tubes to the inside
diameter of the shell cylinder can be specified.
See also:
Tube Layout: Overview
Open Distance at Top of Bundle
Open Distances with Pass Details Specification
 Shell&Tube Open distance on Right Side of
Layout
The distance from the edge of the right-hand column of tubes to the inside
diameter of the shell cylinder can be specified.
See also:
Tube Layout: Overview
Open Distance at Top of Bundle
Open Distances with Pass Details Specification
 Shell&Tube Number of Horizontal Pass Partition
Lanes
Enter the number of horizontal pass partition lanes.
In a vertical exchanger, this should be the lane which is perpendicular with
the inlet nozzle.
This item can normally be omitted if the pass partition layout has been
specified. Shell&Tube assumes that the orientation of the layout with respect
to the flow is so as to minimise the number of pass partition lanes in line with
the flow. If this is not the case in your exchanger, you may find it useful to
explicitly specify the number of horizontal pass partition lanes.
[Shell&Tube will work out whether or not the horizontal pass partitions are in
line with the flow, depending on the orientation of the baffle cut]
 Shell&Tube Vertical Pass Partition Lanes
Enter the number of vertical partition lanes.
In a vertical exchanger, this should be the lane which is in line with the inlet
nozzle.
This item can normally be omitted if the pass partition layout has been
specified. Shell&Tube assumes that the orientation of the layout with respect
to the flow is so as to minimise the number of pass partition lanes in line with
the flow. If this is not the case in your exchanger, you may find it useful to
explicitly specify the number of vertical pass partition lanes.
[Shell&Tube will work out whether or not the vertical pass partitions are in
line with the flow, depending on the orientation of the baffle cut]
 Shell&Tube Number of Tie Rods
The program optimizes the location of the Tie Rods to maximize the number
of tube holes in the layout. Enter the number of Tie Rods, which can be any
even number between 4 and 12, or let Shell&Tube default to the number
required by the TEMA standards.
 Shell&Tube Tie Rod Diameter
Enter the Diameter of the Tie Rods or let Shell&Tube default to the Diameter
required by the TEMA standards.
 Shell&Tube Spacer Diameter
The Spacers slide over the Tie Rods to secure the baffles at the correct
distance apart. Tubes are generally used for Spacers. For example, a 3/8 inch
OD tie rod would have a 5/8 inch OD Tube used as a Spacer.
 Shell&Tube: Replace Tubes by Tie Rods if
necessary
Tie rods are normally located around the outside of the bundle, but if the shell
to bundle clearance is small, it might be necessary to remove some tubes to
make space for the tie rods. This is the normal default. You can, however,
elect to not let this happen, in which case the corresponding tie rods will
appear on the tube layout diagram in a location which is not mechanically
feasible. You can then move them to somewhere suitable using interactive
editing of the tube layout.
The exact location of tie rods does not affect the calculated thermal/hydraulic
performance of an exchanger; the number of tubes does.
See also
Tube Layout: Overview
 Shell&Tube: Flow Pass Number
This input identifies the flow sequence through the various tube pass regions.
The default is set depending on the location of the tube side inlet nozzle.
Check this input carefully if any tube side nozzle is on the side of the
exchanger or if the Pass Layout is not in the standard (horizontal) orientation.
Normally, identifying the region with the inlet flow pass (pass number 1) will
cause the other regions to default correctly. With H-banded layouts, setting
pass number 2 might also be necessary.

See also:
Pass Details
 Shell&Tube: Number of Tube Rows
This input identifies the number of tube rows in a pass region. A row is a
horizontal line of tubes, as it appears on the layout diagram. The default is
set consistent with the pass layout and the total number of rows in the
bundle, with a view to equalizing the number of tubes in each pass region.
Supply a different value if you need to match a specific exchanger or if you
deliberately want a different number of tubes per pass.
If you specify a value different from the default, then the default number of
rows in other pass regions will adjust to be consistent with your input.
When there are two passes in a band, then the number of rows (in the
Standard layout orientation) must be the same in the two passes.

See also:
Pass Details
 Shell&Tube: Number of Tube Columns
This input identifies the number of tube columns in a pass region. A column is
a vertical line of tubes, as it appears on the layout diagram. The default is set
consistent with the pass layout and the total number of columns in the
bundle, with a view to equalizing the number of tubes in each pass region.
Supply a different value if you need to match a specific exchanger or if you
deliberately want a different number of tubes per pass.
If you specify a value different from the default, then the default number of
columns in other pass regions will adjust to be consistent with your input.
When there are two passes in a band, then the number of columns (in the
Standard layout orientation) can be different in the two passes. When there
are two adjacent bands with two passes, the pass partition lane between the
bands (the horizontal lane in the standard layout orientation) must be
continuous, but the other lane (the vertical lane in the standard orientation)
can be discontinuous, depending on your specification of the number of
columns (in the standard layout orientation), or rows (in the other layout
orientation).

See also:
Pass Details
 Shell&Tube: Number of Tubes
The number of tubes in a bundle is strictly the number of potential tube
location, implicit in the number of rows and columns. It does not include
allowance for any tubes subsequently removed to position tie rods.
You can specify the number of tubes in each pass region, if you wish, but you
are advised not to do so before the numbers of tube rows and columns is
correct. If you specify a value which is different from the calculated value,
you will get a warning message.
With the Advanced calculation method (the usual default), the number of
tubes per region, either the default or the value you have input is used in the
tube side thermal and hydraulic calculations.
With the Standard calculation method, all passes are assumed to have the
same number of tubes for tube side heat transfer and pressure drop
calculations.

See also:
Pass Details
 Shell&Tube: Tube in Reference Location
This input applies to staggered layouts, where there is a tube in alternate
locations on the underlying grid of rows and columns. With the standard
layout orientation, the reference location in each pass region is the
intersection of the top row and center-most column. With the other layout
orientation, where the horizontal and vertical axes are interchanged, this
becomes the intersection of the rightmost tube column and the tube row
nearest the horizontal centerline.
The default setting for this item is normally that which gives the most tube
locations in a pass region. In some cases, however, pass regions have linked
tube locations. This applies to U-bends and to bundles with cleaning lanes.
Here the default is set to optimize the overall tube count and if you specify an
input different from the default in one pass region, the defaults in other pass
regions will change accordingly.

See also:
Pass Details
 Shell&Tube: Number of Tubes - all regions
The default of this “input” shows you the total tube count for all pass regions.
It includes all tube locations, including those that may subsequently be lost to
tie rods, and so may differ from the eventual total.
See also:
Pass Details
 Shell&Tube Use separate Outlet Nozzles for
Hot/Cold side Liquid/Vapor flows
Yes
No
 Shell&Tube Use the specified Nozzle
dimensions in Design mode
Yes
No
This option determines whether the specified nozzle sizes will be used in the
current design calculation.
If this is set to ‘No’ Shell&Tube will determine the optimum nozzle sizes for
the conditions specified.
 Shell&Tube Nominal Pipe Size
If using standard pipe for the nozzles, select the required Standard and
Nominal Pipe Size from the drop-down list. The program will look up the
corresponding Nominal Diameter, Actual OD and determine a Wall Thickness
and Actual ID based on an approximate mechanical calculation.
Select ‘Unknown’ if not using standard pipe, then specify an Actual OD, or ID.
 Shell&Tube Nominal Diameter / Actual OD /
Actual ID
Specify the size of the Nozzle by the input of one of the following:
· Nominal Diameter
· Outside Diameter
· Inside Diameter
 Shell&Tube Wall Thickness
Enter the actual Wall Thickness of the Nozzle.
If not specified Shell&Tube will calculate this value.
 Shell&Tube Nozzle Orientation Shell Side
Specify the Orientation of the Nozzle around the circumference of the shell,
when viewing the Nozzle from Front Head of the unit.
 Shell&Tube Distance to Front Tubesheet
Enter the distance from the Nozzle centerline to the Tube Side Face of the
Front Tubesheet.
 Shell&Tube Number of Nozzles
Enter the number of Nozzles per Shell.
 Shell&Tube Multiple Nozzle Spacing
Enter the distance between multiple Nozzles.
 Shell&Tube Nozzle / Impingement Type
Set Default
No Impingement
Yes Impingement
Vapor Belt
Dome
Ignore Nozzle

The purpose of impingement protection is to protect the tubes directly under

the inlet nozzle, by deflecting the bullet shaped flow of high velocity fluids or
the force of entrained droplets.
TEMA recommends that inlet impingement protection be installed under the
following conditions:
· When the rho*V2 through the inlet nozzle exceeds 2232 kg/(m*s2) or
1500 lb/(ft*s2) for non-corrosive, non-abrasive, single phase fluids
· When the rho*V2 through the inlet nozzle exceeds 744 kg/(m*s2) or
500 lb/(ft*s2) for corrosive or abrasive liquids
· When there is a nominally saturated vapor
· When there is a corrosive gas
· When there is two phase flow at the inlet

See also:
Impingement Protection Device
 Shell&Tube Maximum Nozzle RhoV2 Shell Side
Specify a maximum value for the RhoV2 that Shell&Tube will design to within
the Nozzle.

See also:
Impingement
 Shell&Tube Shell Side Nozzle Flange Rating
Specify the required Nozzle Flange Rating on the Shell Side.
This input has no affect on the Thermal calculations.
 Shell&Tube Shell Side Nozzle Flange Type
Specify the required Nozzle Flange Type on the Shell Side.
This input has no affect on the Thermal calculations.
 Shell&Tube Shell Side Nozzle Location options
Use this input to specify whether shell side inlet and outlet nozzles should be
on the same or opposite sides of the shell.
Normally exchangers will be designed with shell side nozzles on opposite sides
of the (horizontal) shell, with inlet at the top if the shell side fluid is hot and
inlet at the bottom if it is cold. This is the sensible option for condensing or
boiling streams. For vertical exchangers, or single phase shell side fluids,
however, there may be advantages in having both nozzles on the same side,
either for convenience of piping, or with up and over baffles, because it
permits an extra baffle to be used, giving improved heat transfer.
This input item is used to define the default locations of the shell side nozzles.
If you explicitly specify the location of both shell side nozzles, this item is not
needed. Remember that with a vertical exchanger, you should imagine the
exchanger laid horizontally when defining shell side nozzle locations and
other features as "top" or "bottom".
 Shell&Tube Location of Nozzle at U-Bend
Before U-bends
Over U-bends
Beyond U-bends
For U-Tube units only, specify the relative location of the Shell Side Nozzle
located at the Rear End of the Shell
 Shell&Tube Nozzle Diameter displayed on TEMA
sheet
Nominal
OD
ID
If standard pipe has been used and ‘Nominal’ is selected, then the nozzle NPS
will be displayed on the TEMA sheet.
 Shell&Tube Nozzle Orientation
The orientation around the shell can be defined for all nozzles, but for tube
side nozzles it can normally be defaulted. For E, G, H, I, J and K-shells it
usually has no effect on the thermal design. For F-shells it is only used in
defining whether the first tube side pass is in co- or countercurrent flow with
the shell side flow, but this item can be specified separately.
Nozzle orientation in horizontal shells is used if gravitational pressure
changes are allowed for, to define whether the overall flow is up or down. For
X-shells the location of the tube side passes within the shell is explicitly
allowed for in Shell&Tube calculations, so the tube side inlet nozzle location is
important.
If you specify a tube side nozzle orientation, it should be defined consistently
with that for shell side nozzles. You can specify each nozzle as being on the
top, bottom or side of a horizontal exchanger. The sides are designated left
and right looking at the exchanger from the tube side inlet end.
The orientation refers to the nozzle position around the shell, not along it. For
vertical exchangers, you should imagine the shell laid horizontal before
defining the orientation.
 Shell&Tube Distance to Tubesheet
Enter the distance from the Nozzle centerline to the Tube Side Face of the
Front Tubesheet.
 Shell&Tube Centerline offset distance
For offset nozzles, enter the distance the nozzle is offset from the centre.
 Shell&Tube Maximum Nozzle RhoV2 Tube Side
Specify a maximum value for the RhoV2 that Shell&Tube will design to within
the Nozzle.
 Shell&Tube Tube Side Nozzle Flange Rating
Specify the required Nozzle Flange Rating on the Tube Side.
This input has no affect on the Thermal calculations.
 Shell&Tube Tube Side Nozzle Flange Type
Specify the required Nozzle Flange Type on the Tube Side.
This input has no affect on the Thermal calculations.
 Shell&Tube Dome OD
Enter the Outside Diameter of the Dome Cylinder.
 Shell&Tube Dome ID
Enter the Inside Diameter of the Dome Cylinder.
 Shell&Tube Vapor Belt Diametric Clearance
Enter the Diametric Clearance between the Outside Diameter of the Shell and
the Inside Diameter of the Vapor Belt. Together with the axial length of the
vapor belt, this is used for determining the flow cross section within the belt,
and hence the vapor belt pressure drop.
 Shell&Tube Vapor Belt Slot Area
Enter the total area of the slot(s) cut into the Shell Cylinder.
 Shell&Tube Vapor Belt Axial Length
Enter the overall length of the Vapor Belt along the axial length of the Shell
Cylinder.
 Shell&Tube Impingement Protection Device
In order to access this item, you should first set Yes, Impingement for the
input Nozzle / Impingement type for the shell side inlet nozzle.
The options are:
· Round Plate
· Square Plate
· Rods
· Dummy Tubes
· None
· Shroud
Round and square plates and impingement rods can be specified in detail and
will appear on the tube layout. Dummy tubes are handled only by very
approximate methods. Shrouds are only modeled when twisted tubes are
specified.
The purpose of impingement protection is to protect the tubes directly under
the inlet nozzle by deflecting the bullet shaped flow of high velocity fluids or
the force of entrained droplets.
TEMA recommends that inlet impingement protection be installed under the
following conditions:
· When the rho*V2 through the inlet nozzle exceeds 2232 kg/(m*s2) or
1500 lb/(ft*s2) for non-corrosive, non-abrasive, single phase fluids
· When the rho*V2 through the inlet nozzle exceeds 744 kg/(m*s2) or
500 lb/(ft*s2) for corrosive or abrasive liquids
· When there is a nominally saturated vapor
· When there is a corrosive gas
· When there is two phase flow at the inlet
If you choose a plate on the bundle, the program automatically removes tubes
under the inlet nozzle so that the shell entrance area equals the cross-
sectional area of the nozzle. This is approximately equal to removing any
tubes within a distance of 1/4 the nozzle diameter under the center of the
nozzle. For purposes of calculating the bundle entrance velocity, the program
defaults to an impingement plate that is circular, unperforated, equal in
diameter to the inside diameter of the nozzle, and approximately 3 mm or 1/8
in. thick.
An alternative is to put a plate in a nozzle dome, which means suspending the
impingement plate in an enlarged nozzle neck, which may be a dome or a
cone.
Both types have their advantages and disadvantages. If the plate is on the
bundle, the flow is more widely distributed, and there is neither the expense
for the enlarged nozzle neck nor the increased potential of fabrication
problems when cutting a large hole in the shell (as can often happen with
vapor inlet nozzles). However, since tubes are removed, it might require
larger diameter shell, tubesheets, flanges, etc. Especially in cases where the
tubesheets and/or shell are made of alloy and the inlet nozzle is not large, the
impingement plate in the nozzle dome can be significantly less expensive.
For some special applications, the plate can be perforated. The primary
advantage being that the perforations help reduce the velocity into the bundle.
The main concern with perforated plates is that flow through the holes could
cause localized erosion for certain tube materials.
See also:
Nozzle / Impingement Type
 Shell&Tube Impingement Plate Diameter
Enter the Diameter of the round Impingement Plate.
The program will use this input to determine the position and the dimension
of the impingement plate This input is not required if you have already
specified the shell inlet nozzle OD.
The default is the shell inlet nozzle O.D.
 Shell&Tube Impingement Plate Length (parallel
to tube axis)
Enter the Length of the square Impingement Plate.
The program will use this input to determine the position of the impingement
plate.
This input is not required if you have already specified the Shell Inlet Nozzle
Outside Diameter.
The default is the Shell Inlet Nozzle Outside Diameter.
 Shell&Tube Impingement Plate Width (normal
to tube axis)
Enter the Width of the square Impingement Plate.
The program will use this input to determine the position of the impingement
plate.
This input is not required if you have already specified the Shell Inlet Nozzle
Outside Diameter.
The default is the Shell Inlet Nozzle Outside Diameter.
 Shell&Tube Impingement Plate Thickness
Enter the Thickness of the Impingement Plate
The default is 6.35 mm or 0.25 inch
 Shell&Tube Impingement Plate Distance in
from Shell ID
Enter the distance from the Shell Inside Diameter to the face of the
Impingement Plate
The default is the top row of tubes
 Shell&Tube Impingement Plate clearance to
Tube Edge
Enter the spacing between the (bottom) surface of the impingement plate and
the (top) surface of the tubes immediately adjacent to it. The default is
normally zero - that is the plate is touching the tubes. The exception is if you
specify a nozzle with a Dome, in which case the impingement plate is located
at the shell/dome intersection.
You can modify this item by editing the main input, or by editing the Tube
Bundle Layout, diagram, including by nudging the impingement plate to a
different location.
 Shell&Tube Impingement Plate Perforated Area
%
For perforated Impingement Plates, enter the percentage of the total area
that is perforated
 Shell&Tube: Rows of Impingement Rods
When the Impingement device is set to Impingement Rods, you can specify
the number of lines of such rods which are located under the inlet nozzle. The
norm is two or three.

See also:
Impingement Rod Layout
Impingement Rod Diameter
 Shell&Tube: Impingement Rod Layout
When the Impingement device is set to Impingement Rods, you can specify
the layout of the lines of rods. Note that when a 30 degree layout is selected,
this refers to the flow direction relative to the inlet nozzle.
The impingement rod pitch is set equal to the tube pitch and cannot be
specified independently.
See also:
Rows of Impingement Rods
 Shell&Tube: Impingement Rod Diameter
When the Impingement device is set to Impingement Rods, you can specify
the diameter of these rods. A value smaller than the tube diameter is often
appropriate.
See also:
Rows of Impingement Rods
 Shell&Tube Pipework Loss Calculation
Set Default
Percent of Liquid Head
From Pipework

There are two options for calculating the pressure loss in the pipework
connecting a thermosiphon reboiler to a column. The first is simply to specify
the pressure loss as a percentage of the liquid head driving the thermosiphon
flow – derived from the difference in height between the liquid surface in the
column, and the exchanger inlet. This has the benefit that no information
need be provided about the actual pipework geometry, making the option
useful at early stages of a Design, when no pipework information is available.
The second option is to actually specify details about the pipework, both inlet
to the exchanger from the column, and outlet from the exchanger (return to
the column). This option is recommended for Simulation calculations which
aim to find the thermosiphon flow.
In a Thermosiphon Design calculation, the flow and driving head are fixed,
and losses in the inlet and outlet pipe are pre-calculated – using whichever of
the above option is specified – to determine the exchanger inlet and outlet
conditions, and the maximum permitted pressure loss, before the Design
calculation begins.
 Shell&Tube Percent Head Loss in Inlet Pipe
This value is used when you elect to specify pipework losses for a
thermosiphon reboiler in the simple percentage form, rather than specifying
the geometric detail of the pipework.
Specify the percentage of the liquid head driving the thermosiphon flow that
is lost in the pipework taking liquid from the bottom of the column to the
exchanger.
Low values will generally give lower thermosiphon exit qualities. High values
will generally reduce the thermosiphon flow, and increase the exit quality.
Low values may increase the risk of flow instabilities.
In a fixed flow thermosiphon calculation, there will in general be a pressure
imbalance around the thermosiphon flow circuit. This appears in the results as
unaccounted pressure change in the inlet and/or outlet circuits.
 Shell&Tube Percent Head Loss in Outlet Pipe
This value is used when you elect to specify pipework losses for a
thermosiphon reboiler in the simple percentage form, rather than specifying
the geometric detail of the pipework.
Specify the percentage of the liquid head driving the thermosiphon flow that
is lost in the pipework returning the two phase flow from the reboiler to the
column.
When the percent of head loss option is used for the outlet pipe, no separate
allowance is made for gravitational and accelerational pressure changes in
this pipe. These are normally small, but they are all lumped together with the
frictional change, when the percent head loss option is used.
Low values will generally be beneficial, both in improving the exchanger
performance (by reducing pressures and boiling temperatures in the reboiler,)
and in improving thermosiphon flow stability
In a fixed flow thermosiphon calculation, there will in general be a pressure
imbalance around the thermosiphon flow circuit. This appears in the results as
unaccounted pressure change in the inlet and/or outlet circuits.
 Shell&Tube Height of Column Liquid Level
For a thermosiphon, you must specify the height of the liquid surface in the
column which is driving the flow through the exchanger.
The reference point from which you measure the height could be the bottom
of the column, or any other suitable datum. You must however use the same
datum for defining the all three key heights.

See Also:
Horizontal Shell Side Reboiler
Vertical Tube Side Reboiler
 Shell&Tube Height of Heat Transfer Region
Inlet
For a thermosiphon, you must specify the height of the exchanger inlet for
the thermosiphon stream. For a shell side reboiler this is the point at which
the centre line of the inlet nozzle intersects the cylinder forming the inner
surface of the shell. For a vertical tube side reboiler, it is the bottom of the
tubes. For a horizontal tube side reboiler, it is the exchanger axis.
The reference point from which you measure the height can be any suitable
datum. You must however use the same datum for defining all three key
heights,

See Also:
Horizontal Shell Side Reboiler
Vertical Tube Side Reboiler
 Shell&Tube Height of Return Line to Column
For a thermosiphon, you must specify the height of the centerline of the
return pipe from the thermosiphon at the point where it enters the column.
The reference point from which you measure the height can be any suitable
datum. You must however use the same datum for defining all three key
heights

See Also:
Horizontal Shell Side Reboiler
Vertical Tube Side Reboiler
 Shell&Tube Inlet Circuit Element
Up to 10 elements of the following type can be selected.
Not Defined
This option means that an element of thermosiphon pipework that appears in
the table does not have any input values supplied, or if supplied they are
ignored by the program.
Normal pipework
All the pipework of a given diameter can be combined together into a single
element. It does not matter whether it is horizontal or vertical. If however
there is some pipework with a different diameter that should be defined as a
separate element.
Arc Bends
For these you must specify the diameter, the centre-line arc radius, and the
number of such bends in series.
Bends
These are sharp bends: specify the diameter and the number of such bends in
series.
General items
These can be used for valves, flowmeters or any other obstruction causing a
pressure loss. You must specify the number of velocity heads lost for each
general item.
In general you should specify the elements in the order in which flow passes
through them, but this is only important when there is a change in diameter
or a manifold. In simple cases, with just pipe and bends, all of the same
diameter, the order does not matter.
See Also:
Example 1. Vertical Thermosiphon
Example 2. Horizontal Thermosiphon
 Shell&Tube Internal Diameter
You can specify the internal diameter of every element in the inlet or outlet
circuit pipework in a thermosiphon circuit. If there is a change in diameter,
two separate elements should be defined.
If you omit the diameter, it will default to the diameter of the preceding
element, if there is one, or to the diameter of the appropriate exchanger
nozzle (inlet or outlet) if there is not.
 Shell&Tube Length (pipe) or Radius (arc)
This input item is used for length dimensions associated with thermosiphon
inlet and outlet circuit elements.
For pipework, you should specify the total length of pipework with a given
diameter. If there are several lengths separated by bends, it is easier to
specify one element with the total length, rather than three separate
elements
For an arc bend, you should input the bend centerline radius.
For ordinary bends, and general items this item is not used and should be left
blank.
 Shell&Tube Velocity Heads (general element)
For a general element, you must specify the number of velocity heads lost in
that element.
The velocity heads will be based on the diameter you specify for this item. If
the item is a valve, the velocity heads will depend on its degree of closure.
For other elements (pipework and bends) this item is not needed and should
be left blank.
A negative number of velocity heads lost can be input, to represent a
pressure increase, caused for example by the pump in a pumped
thermosiphon.
 Shell&Tube Elements in Series
This element defines the number of elements (bends, pipework etc.) in series,
in either the inlet circuit or outlet circuit as appropriate. If you leave it blank
it will default to 1. It is most useful for the number of bends. For other
elements it can be used, but it is unlikely to be necessary, so any value other
than unity will result in a warning.
In a complicated manifolding system, there may be different numbers of
bends in two lines in parallel. Specify an average number for the number in
series. It does not have to be an integer.
 Shell&Tube Elements in Parallel
This item should be left blank, and will default to unity, except in the special
case where there are either multiple exchangers in parallel, or multiple inlet
or outlet nozzles. You can use this item to define whether the pipework for
each exchanger is separate or combined.
For example if there are two exchangers in parallel initially fed through a
single six inch line, but then manifolded together using four inch pipe, you
might perhaps specify four circuit elements.
Pipework, 6 inch diameter (elements in parallel left blank to indicate one)
Bends in 6 inch diameter line (elements in parallel left blank to indicate one)
Pipework 4 inch diameter (two in parallel)
Bends in 6 inch diameter line (two in parallel)
Shell&Tube will deduce the presence of a manifold, when the number of items
in parallel changes, and make allowance for pressure loss in it. Note that this
is the one case where the order of elements is important. The elements
should be specified in the flow direction.
Not that in a complicated manifolding system, there may be different numbers
of bends in two lines in parallel. Specify an average number for the number in
series. It does not have to be an integer.
 Shell&Tube Outlet Circuit Element
Up to 10 elements of the following type can be selected.
Not Defined
This option means that an element of thermosiphon pipework that appears in
the table does not have any input values supplied, or if supplied they are
ignored by the program.
Vertical Pipework
All the vertical pipework of a given diameter can be combined together into a
single element. If there is some pipework with a different diameter, that
should be defined as a separate element.
Horizontal Pipework
All the horizontal pipework of a given diameter can be combined together into
a single element. If there is some pipework with a different diameter, that
should be defined as a separate element.
Arc Bends
For these you must specify the diameter the arc radius, and the number of
such bends
Bends
These are sharp bends: specify the diameter, and the number of such bends.
General Items
These can be used for valves, flowmeters or any other obstruction causing a
pressure loss. You must specify the number of velocity heads lost for each
general item.
In general you should specify the elements in the order in which flow passes
through them, but this is only important when there is a change in diameter
or a manifold. In simple cases, with just pipe and bends, the order does not
matter.
See Also:
Example 1. Vertical Thermosiphon
Example 2. Horizontal Thermosiphon
 Shell&Tube Thermosiphon Type (calculation
modes)
In a Thermosiphon Reboiler, the flow of the (cold) thermosiphon stream is
determined by a pressure balance around the circuit connecting the
exchanger to the bottom of the column. The gravitational head of liquid
between the liquid surface in the column and the exchanger inlet is balanced
by frictional losses in the exchanger and the inlet and return pipework,
combined with gravitational decreases in the exchanger and return pipe.
Pipework losses are an important factor. These can be calculated either from
an explicit specification of the pipework components or from specified
percentages of the driving gravity head, lost in the inlet and outlet pipework.
Thermosiphon Reboilers can be handled by all the program calculation modes.
Design, Check-Rating and Maximum Fouling are all based on a “Fixed flow”
calculation. In this case, the program calculates any unaccounted pressure
losses in the inlet and/or outlet lines needed to achieve a pressure balance.
In Simulation mode, a “Find Flow” option is available, where any cold stream
flowrate you specify in the process data, either explicitly or implicitly, is taken
as an initial estimate only. The program then adjusts the flow to get a
pressure balance around the thermosiphon circuit.
The two pipework loss options are available in all modes and with both flow
options. For Design, the percentage of the driving head is usually most
convenient, since pipework details are unknown. For Simulation calculations,
with “Find Flow”, explicit specification of the pipework components is
recommended.
For all thermosiphon calculations, three heights are required:
· The height of the liquid level in the column
· The height of the exchanger inlet
· The height of the point where the return line enters the column
These are all relative to any datum you select, since only height differences
matter. The first two heights, which determine the head driving the
thermosiphon flow, are the most important. The return line height is used
only to estimate gravitational changes in the outlet line, which are usually
relatively small.
For all modes except Simulation, default values of these three heights are
available. However, these defaults are fairly arbitrary and should be used with
caution. If you are unsure what values are appropriate, try changing the
exchanger inlet height to determine how this affects the calculated results.
Sometimes the effect will be small, in other cases, particularly where sub
atmospheric pressures are involved, the effect can be significant.
In Design mode, the thermosiphon flow and the three heights are fixed. The
heat load and, by implication, the outlet quality are specified. Before the
Design calculation begins, the program calculates the pressure changes in the
inlet and outlet pipework (in order to determine the exchanger inlet and
outlet conditions) and the maximum permitted pressure drop implicit in a
pressure balance around the thermosiphon circuit.
The Design calculation will select an exchanger size to match the heat load
and pressure drop constraints. Normally, the predicted pressure loss will be
slightly lower than the maximum permitted loss, so there will be a small
unaccounted loss reported which would be needed for a pressure balance
around the circuit.
If, when Designing a thermosiphon reboiler, you have some freedom as to the
height at which the exchanger is located, you should adjust the exchanger
inlet height and repeat the Design to see whether significant improvements
can be achieved.
Either the Standard Method or the Advanced method can be used for
thermosiphon reboiler calculations. The advanced method has the benefit that
it offers a range of pressure calculation options. For thermosiphon reboilers,
the option to back-calculate the inlet pressure for a given outlet pressure is
particularly appropriate, since this ensures that any unaccounted pressure
drop in a Fixed Flow calculation is ascribed to the inlet circuit, where it will
usually give enhanced stability, and where there is usually most scope for
adjustment of the pressure loss.
Thermosiphon stability results are available in all modes, but should be
treated with caution for Fixed Flow calculations when there is a significant
pressure imbalance.
The Calculation Type relates to the cold (boiling) stream flow only. If the
heating stream is condensing (as it usually is), its flowrate is usually adjusted
to give complete condensation (See hot stream flow).

See also:
Thermosiphons
 Shell&Tube Designing Thermosiphon Reboilers
Using Design Mode for a thermosiphon reboiler is straightforward, but it is
useful to understand which parameters are being fixed and which are
optimized.
As for all thermosiphon calculations, the pressure above the liquid in the
column is taken as the fixed reference. Pressures elsewhere depend on
· The thermosiphon flowrate
· The vertical heights of the exchanger inlet
· The return line to the column relative to the liquid surface in the column
Fundamentally the thermosiphon flowrate, heat load, and exit quality are
fixed in a Design calculation. Pressure changes in the inlet and outlet line are
determined before the Design iteration begins, and the maximum permitted
pressure change is adjusted from the initial estimate to the value required to
give a pressure balance around the thermosiphon circuit.
There is an option under Methods | Correlations | Pressure drop for whether
or not gravitational pressure changes should be included in the pressure
change calculation. By default, gravity changes are included in the pressure
drop for a Thermosiphon Design. It is important to specify the three vertical
heights, liquid surface, exchanger inlet, and return to column. Although
defaults are available, these are fairly arbitrary. You should try several values
of the exchanger inlet height to determine whether this has a significant
effect on the exchanger design. This can be critical for vacuum
thermosiphons. It may also be appropriate to explore the effect of changing
the reboiler outlet quality, insofar as this may be permitted by the reboiler
process specifications.
For a vertical thermosiphon reboiler, the design calculation determines the
exchanger length, but does not explicitly match this to the height of the
column return. For a close coupled reboiler, where the outlet pipe is a simple
horizontal line to the column, it may also be appropriate to adjust the
exchanger inlet height. You can force a design with a specified exchanger
(tube) length by setting the minimum and maximum such lengths to be equal,
once you have fixed the exchanger inlet height and the return line height.

See also:
Thermosiphons
 Shell&Tube Service Class
If you select low temperature (design temperature less than -50°F) or lethal
service (exchanger contains a lethal substance), the program selects the
corresponding Code requirements for that class, such as full radiography for
butt welds and PWHT for carbon steel construction.
 Shell&Tube TEMA Class
If you want the heat exchanger to be built according to TEMA standards,
select the appropriate TEMA class: R, C, or R. If TEMA is not a design
requirement, then specify Code only, and program will use only the design
code to determine the mechanical design.
 Shell&Tube Material Standard
ASME, AFNOR, DIN, JIS, EN - determines the selection of materials listed in
the input for materials of construction. By default the program uses the
standards defined in the Program Settings under Tools.
 Shell&Tube Dimensional Standard
ANSI (American), ISO (International) or DIN (German) - applies to such
things as pipe cylinder dimensions, nozzle flange ratings, and bolt sizes. DIN
also encompasses other construction standards such as standard tube pitches.
Other
 Shell&Tube Design Pressure
Used in the mechanical design calculations, the specified design pressure
influences the shell, head, and tubesheet required thicknesses and therefore
affects the thermal design. If you do not specify a value, the program defaults
to the operating pressure plus 10% rounded up to a logical increment. This is
in gauge pressure, which is one atmosphere less than the equivalent absolute
pressure.
 Shell&Tube Vacuum Design Pressure
By default vacuum design pressure is not calculated for vacuum service.
However, if the heat exchanger is going to operate under a full or partial
vacuum, you should specify a vacuum service design pressure.
The basic mechanical design calculations do not consider external pressure;
therefore, this item will have no effect on the thermal design from the
program.
 Shell&Tube Test Pressure
This is the pressure at which the manufacturer will test the heat exchanger.
This has no effect on the thermal design, but is included to make the heat
exchanger specification more complete. The default is the values required by
the Design Code.
 Shell&Tube Corrosion Allowance
This is included in the thickness calculations for cylinders and tubesheets and
therefore has a subtle effect on thermal design. The default is 0.125 inches or
3.2 mm for carbon steel; 0 for other materials.
program defaults to 3.18mm
 Shell&Tube Radiography
The options are:
· Set default
· None
· Spot
· Full

The level of radiography specified for the Shell Side and Tube side has no
affect on the thermal design, but will affect the calculated cost of the heat
exchanger.
 Shell&Tube Use Shell ID or OD as reference
You can identify whether shell diameters used in the Design process, including
any shell size limits specified, should be based on the shell internal or
external diameter.
 Shell&Tube Allow Baffles under Nozzle
Normally nozzles are located in end spaces, before the first baffle, or after the
last baffle, to give well defined crossflow in both end spaces. Sometimes,
particularly with double segmental baffles, a case can be made for putting the
first baffle under a nozzle, if the benefit, from a vibration perspective, of
reduced endspace length outweighs any loss of heat transfer effectiveness in
the endspace.
 Shell&Tube Use Proportional Baffle Cut
The default design option is to use a proportional baffle cut, that is to use a
cut that gives a flow area within the cut which is the same as the bundle cross
flow area within a baffle pitch. The baffle cut must be correctly located with
respect to the lines of tubes, so only approximate equality of the two areas
can be achieved.
The alternative is to optimize the cut, by exploring whether a better design
can be achieved by moving it one or two tube lines towards or away from the
baffle centre. This is sometimes useful in achieving a better design. The down
side is that the design calculation may take significantly longer. It is probably
sensible to run with a proportional cut first and then restrict the range of the
design search when seeking to optimize the cut.
 Shell&Tube Number of Rows between Sealing
Strips
You can specify the target number of rows between sealing strips. The default
is normally adequate. The Design process will chose a slightly different
number, if necessary to make sure that sealing strips are sensibly located.
You may want to supply a lower value than the default if the flow analysis
results suggest that the bundle bypass flow is high. Reducing the number of
rows between strips will give a higher crossflow through the bundle, which
will give both higher shell side coefficients and higher shell side pressure
drops.
 Shell&Tube Percent of Tubes to be Plugged
Your can specify that the Design process allows for some percentage of tubes
to be plugged. This is one way of specifying a design margin, particularly if
experience suggests that plugging tubes may be necessary at some point in
the operating life of the exchanger.
 Shell&Tube Remove Tubes for Vapor
Disengagement Space in Flooded Evaporator
When Designing a flooded evaporator, you should specify and X-shell, and can
specify her that you want tubes to be removed at the top of the bundle.
This item is not needed for kettle reboilers, where a larger shell, rather than
removal of tubes with the bundle, is used for vapor disengagement, nor is it
needed for modes other than Design, where you can use the option to specify
clearance at the top of the bundle, under exchanger geometry.
 Shell&Tube Percent of Shell Diameter for
Disengagement
When Designing a flooded evaporator, you should specify and X-shell, and can
specify whether or not you want tubes removes at the top of the bundle here
the percentage of tubes to be removed at the top of the bundle. If you select
tube removal, then specify here the percentage of the shell diameter without
tubes.
This item is not needed for kettle reboilers, where a larger shell, rather than
removal of tubes with the bundle, is used for vapor disengagement.
When not in Design mode, this item does not apply. You can specify the opens
space at the top of the bundle using options under Exchanger Geometry /
Bundle Layout / Bundle Limits.
 Shell&Tube Variable Baffle Pitch: First to Last
Pitch Ratio
For Designs using variable baffle pitch, you can identify here the target ratio
of the first baffle pitch (nearest the shell side inlet) to the last pitch (nearest
the outlet). Remember to use the Advanced Calculation Method, and set the
number of baffle regions (on Exchanger Geometry / Baffles / Variable Baffle
Pitches) to two, three or four, if you want to design with different pitches in
different parts of the exchanger.
The ratio should be more than one for hot streams, where volume flows
decrease, and less than one for cold streams, where volume flows increase
It is hard to predict what the best value of this ratio should be. You would
normally first get a design with constant baffle pitch, and if there is evidence
that the shell side is limiting, and the shell side volume flow changes
significantly along the exchanger, try running with one or two different values
of the first /last pitch ratio. It may also be profitable to generate a checking
case, and adjust the baffle pitch regions manually to produce a best Design.
The Design process uses the standard algorithm for selecting the number of
baffles and (mean) baffle spacing. It then adjusts the number of baffle spaces
in each region to be approximately the same, putting more in the region(s)
with smaller baffles spaces if necessary. This simple selection procedure is
unlikely to produce the optimum baffle pitch variation, but should give an
indication how useful variable baffle pitches might be in a particular case.
 Shell&Tube Shell Diameter Limits
You can specify the minimum and maximum shell diameters which the Design
search should consider, together with the search increment. Normally the
default values will be appropriate. These parameters are used to establish a
set of possible diameters, beginning at the minimum specified, and increasing
by the increment until the maximum is reached or exceeded. The specified
maximum is always included in the set of values established.
The Design logic will then identify a minimum starting diameter, based on
criteria such as minimum number of tubes for a given tube side maximum
velocity, maximum plausible heat transfer coefficient, or the size of any
specified nozzles. This will be used to eliminate smaller diameters from the
set.
The Design logic will investigate progressively higher diameters, until a best
design is found. It will usually also investigate a couple of higher diameters,
in case a further improvement can be made. Large diameters are not
investigated once it becomes obvious they will cost more than the best design
cost.
If you want to fix a particular diameter, set the minimum and maximum
diameters to be the same.

[Input items 116.3, 116.4, 180.1 = minimum, increment, maximum shell

diameter]
 Shell&Tube Tube Length Limits
You can specify the minimum and maximum tube length which the Design
search should consider, together with the search increment. Normally the
default values will be appropriate. These parameters are used to establish a
set of possible lengths, beginning at the minimum specified, and increasing by
the increment until the maximum is reached or exceeded. The specified
maximum is always included in the set of values established.
Note that the defaults depend on the dimensional standard specified under
Application Options.
During the Design search, designs with the maximum tube length (and
minimum baffle pitch) are investigated first for each shell diameter. Only if
the surface area is adequate (or nearly so) in this first case are smaller tube
lengths (and other baffle pitches) investigated.

[Input items 107.1-3 = minimum, maximum, incremental tube length]

 Shell&Tube Tube Passes Limits
You can specify the minimum and maximum number of tube passes to be
investigated, together with the set of possible values. The default is just to
consider even numbers of passes, plus single pass, but not other odd numbers
of passes.
The default values are normally acceptable. Reducing the maximum number
will usually have little or no effect on the time taken for the design, since
higher numbers of passes are not investigated once it becomes clear that they
could not give an acceptable pressure drop in a reasonably sized exchanger.
Starting the search at two rather than one pass will sometimes have a
significant effect on Design time, but you should only do this if you are
confident that the specified duty is possible with multiple passes in the
minimum specified number of shells in series.

[Input items 107.4-5 = maximum, minimum number of passes]

 Shell&Tube Baffle Spacing Limits
You can specify the minimum and maximum baffle pitch to be used in the
design search
The program then identifies a set of baffle pitches, but not a uniformly spaced
set. The set is chosen to give a representative range of mass fluxes.
The default values of baffle pitch will normally be acceptable, but if the
selected design has a large pitch, and a small number of baffles, you may be
able to improve it by adjusting the pitch, and hence the end space lengths,
slightly.

[Input items 180.4, 182.3 = maximum, minimum baffle pitch]

 Shell&Tube Baffle Cut Limits
You specify a maximum and minimum baffle cut if you wish, but these are
restrictive limits, rather than a range of parameters which will be searched
over.
A single optimum baffle cut is normally selected form each baffle spacing,
based on achieving approximately equal crossflow and window flow areas.
Baffle cuts are always located correctly with respect to tube lines, so the
equal area objective is always approximate.
There is a separate input option to investigate the effect of baffle cut on
design more comprehensively. This involves shifting the cut by one or two
tubes lines each side of the initial optimum to see if an improvement can be
improved. The baffle cut limits option potentially sets a restriction on cuts
that are investigated in this case.

[Input items 182.2 = maximum, minimum cut]

 Shell&Tube Shells in Series and Parallel
You can specify the maximum and minimum number of shells in series to be
investigated in the Design search.
The Design search does not stop once an optimum design is found, but always
tries to investigate one more shell in series, and one more shell in parallel
than the best design, subject to the specified limits. Since in most cases the
best design is a single shell, the relatively high defaults for shells in series
and parallel become irrelevant. You can if you wish impose the limit of a
single shell, but this runs the risk of not finding improved designs with two (or
more) smaller shells, and of not finding any designs in some cases where two
or more tube side passes must be used.

[Input items 180.2-3 = maximum in series, parallel]

 Shell&Tube Use Pipe for Shells below this
Diameter
Smaller shells diameters are normally selected based on pipe sizes, while
larger shells are assumed to be welded and can thus be of any required
diameter. You can reduce the limit up to which pipe sizes are used if you
wish.

[Input item 021.4]

 Shell&Tube Velocity Limits
You can specify a minimum and maximum velocity for each side of the
exchanger.
In most cases only the minimum and maximum tube side velocity limits affect
the design, since these affect the maximum and minimum limits on number of
tubes per pass, and hence restrict the range of shell size investigated, for a
given number of passes and shells in parallel.
The restrictions on shell side velocities have a similar effect for axial shell side
flows, but are not used for baffled or other crossflow exchangers. Crossflow
velocities have significant spatial variation within each baffle region and
window flow, with potentially much higher than average values in some
regions, such as adjacent to sealing strips and the baffle cut, and much lower
than average values in other places, even including areas of recirculation just
downs stream of the baffle cut. Crossflow velocities in the program output are
“nominal” velocities, which make no allowance for such effects.
The ranges of baffle spacing and shell diameters permitted are the main
parameters affecting shell side velocities, and these should be used instead of
explicit velocity limit specification for baffled shell side exchangers.

[Input items 207.3-4 = minimum, maximum velocity]

 Shell&Tube Target Pressure Drop in Nozzles
You can specify a target pressure drop in the exchanger nozzles. This is as a
percentage of the maximum permitted pressure drop, not the actual
exchanger pressure drop.
These input items are used in all calculation modes, not just Design, if you
omit to explicitly specify any nozzle size. The maximum relates to the sum of
all nozzles. The split between the two nozzles on each size may be unequal, if
this is beneficial overall.
This input is only a target. Lower pressure losses will often result, because of
other nozzle constraints. Occasionally larger values will be needed. Very often
it will turn out that losses elsewhere in the exchanger are well below the
permitted limit, so the nozzle losses as a percentage of the actual loss may be
much higher than the specified percentage of the maximum loss.

[Input item 207.2]

 Shell&Tube Maximum Entrainment Ratio
For kettles, you can specify a maximum entrainment ratio which is used to
size the large shell diameter in Design mode, or if you do not explicitly input
it in other modes.

[Input item 181.4]

 Shell&Tube Allow Local Temperature Crosses
This Design mode item is not yet implemented. It will provide a method of
setting the minimum number of shells in series, to ensure that in each shell
the hot outlet temperature is above the cold outlet temperature. You can
repeat the design with an increased value for the minimum number of shells
in series, if a first design gives a temperature cross.
Temperature crosses of this kind are not in themselves a problem. They are
no problem whatsoever in single pass exchangers, and in multi-pass
exchangers they will not be a problem even if at some point the shell side
temperature and one of the tube side temperatures cross. These crosses are
handled correctly by the program. Such crosses may, however indicate that
the exchanger is approaching the limiting load achievable with any size
exchange with this particular exchanger configuration.
Non-physical temperature crosses are not permitted by the program.

[Input item 020.1]

 Shell&Tube Design Search Thoroughness
Options
The Design search procedure makes a number of assumption that can in some
cases involve it searching for Designs with exchanger configurations which
are unlikely to give a useful Design, but possible could in some unusual
circumstances. This option lets you make the search algorithm less
conservative, and hence in some cases much quicker, but at the expense of
introducing a risk of missing some possible Designs.

[Input item 190.5]

 Shell&Tube Basis for Design Optimization
Normally the Design optimization is based on minimum exchanger cost, but
you can select that it is based on minimum exchanger area, if you have
reason to think the minimum cost solution is inappropriate.

[Input item 20.4]

 Shell&Tube Highest Cost or Area Ratio
Considered
This item gives a multiplier such that Design are rejected, and the Design
search is directed elsewhere once exchangers exceed this multiplier of the
minimum cost design (or minimum area Design if you are optimizing on
area).
Note that the multiplier is applied to the current best (minimum cost OK)
design. (OK means meeting area ratio and pressure drop constraints). If the
design search subsequently finds a better “best” design, cases previously
accepted are retained, so the final list of Designs can contain a wider range of
cost than that implied by the ratio specified here.

[Input item 020.5]

 Shell&Tube Minimum Percent Excess Surface
Area Required
For a Design to be marked “OK” its actual surface area must be 100% or
more of the required surface area for the specified duty and exchanger size.
You can specify here that the criterion is more than 100% (specify the excess
over 100%) so that all acceptable Designs effectively have this degree of
safety margin.
The output will still show Designs with a slightly lower area ratio, but they will
be marked “near” rather than OK.

[Input item 181.5]

 Shell&Tube Show Units that meet Minimum
Actual/Required Surface Area Ratio
The Design search not only identifies “OK” designs, which meet all the area
ratio and pressure drop constraints, but also “near” designs, which just miss
one or more of these constraints. This input identifies the minimum area ratio
for which a design can be considered “near”.
You may be able to convert a “near” Design to an “OK” one by making minor
changes to features such as tube length, baffle pitch, or end space lengths.

[Input item 023.4]

 Shell&Tube Show Units that meet Maximum
Actual/Allowed Hot Side Pressure Drop Ratio
The Design search not only identifies “OK” designs, which meet all the area
ratio and pressure drop constraints, but also “near” designs, which just miss
one or more of these constraints. Input items let you revise the maximum
pressure drop ratio, for either the hot side or the cold side, for which a design
can be considered “near”. The pressure drop ratio is the ratio of the actual to
the permitted pressure drop.
The maximum pressure drop ratio may affect the extent and speed of the
Design search, though usually only to a minor extent.
You may be able to convert a “near” Design to an “OK” one by making minor
changes to features such as tube length, baffle pitch, or end space lengths.
Alternatively you may decide that the cost benefits of a “near” design are so
great that the allowed pressure drop should be increased.
 Shell&Tube Show Units that meet Maximum
Actual/Allowed Cold Side Pressure Drop Ratio
The Design search not only identifies “OK” designs, which meet all the area
ratio and pressure drop constraints, but also “near” designs, which just miss
one or more of these constraints. Input items let you revise the maximum
pressure drop ratio, for either the hot side or the cold side, for which a design
can be considered “near”. The pressure drop ratio is the ratio of the actual to
the permitted pressure drop.
The maximum pressure drop ratio may affect the extent and speed of the
Design search, though usually only to a minor extent.
You may be able to convert a “near” Design to an “OK” one by making minor
changes to features such as tube length, baffle pitch, or end space lengths.
Alternatively you may decide that the cost benefits of a “near” design are so
great that the allowed pressure drop should be increased.
 Shell&Tube Number of Designs before Option to
Stop
This item should not normally be input.
If a Design calculation is taking a long time there is a user-interrupt option to
“stop” the iteration. This item provides a margin on how abruptly the stop is
implemented.

[Input item 183.4]

 Shell&Tube Heat Transfer Coefficient
Normally, the film coefficients are two of the primary values you want the
program to calculate. However, there may be cases where you want to force
the program to use a specific coefficient, perhaps to simulate a situation that
the program does not explicitly cover.
For the two liquid phase option Shell&Tube generates an effective composite
phase for use in the heat transfer and pressure loss calculations.
 Shell&Tube Heat Transfer Coefficient Multiplier
You can specify a factor that becomes a multiplier on the film coefficient,
which is calculated by the program. You may want to use a multiplier greater
than 1 if you have a construction enhancement that is not covered by the
program, for example tube inserts or internally finned tubes. You can use a
multiplier of less than 1 to establish a safety factor on a film coefficient. This
would make sense if you were unsure of the composition or properties of a
fluid stream.
For the two liquid phase option Shell&Tube generates an effective composite
phase for use in the heat transfer and pressure loss calculations
 Shell&Tube U-bend Area used for Heat Transfer
Since the shell side fluid does not usually flow over the U-bends in the same
way as it flows over the straight portion, the effectiveness of the area in the
U-bends is limited.
 Shell&Tube Fraction of Tube Area submerged
for Shell Side Condensers
This item applies to horizontal shell side condensers, and is applicable when
there is a loop seal, or some other device or geometric feature that causes
some of the tubes in the exchanger to be submerged under condensate.
You specify the average fraction of the heat transfer surface area in a
horizontal shell side condenser that is submerged by condensate. The value
that you enter is used by the program to calculate the velocity and hence the
heat transfer coefficient for condensate cooling. The vapor velocity used in
the gas-phase heat transfer coefficient is also adjusted to take account of the
reduced vapor flow area. The program compares your input value with the
calculated fraction of the surface that needs to be submerged to meet the
condensate cooling duty.
You should use this item when you wish to use a loop seal or liquid level
controller to deliberately flood some of the tubes by condensate. You can
iteratively adjust the input value in successive runs until the input and
calculated submergence are in agreement.
 Shell&Tube Weir Height above Bundle for
Kettle Reboilers
Enter the height of the Weir above the top of the bundle. If omitted, this item
is assumed to be zero that is the top of the weir is level with the top of the
outer tube limit circle of the bundle.
The height of the weir is taken as defining the head of liquid providing the
driving force for re-circulation within a kettle
 Shell&Tube Pressure Drop Multiplier
A value entered here will scale the frictional pressure drop calculated for the
stream. The value entered can be greater or less than 1.
The multiplier affects the pressure change in the tubes or the overall pressure
drop in the shell. It is not applied to the nozzle losses.
The item allows you to cater for enhanced surfaces, tube inserts or other
enhancement devices which are not currently modeled by the program...
 Shell&Tube Falling Film Evaporator Distributor
Velocity Heads for Pressure Loss Calculation
Special distribution devices are often used to achieve uniform flow distribution
of the liquid in-flow to all the tubes of a falling film evaporator (FFE).
You may indicate the extent of the pressure loss in such a device by
specifying the number of velocity heads lost in it. These are based on the
liquid flow rate in, and assume the total flow area of the tube is occupied by
the liquid.
This item applies only FFE's. It is used in both Performance and Design
calculations. The default is zero (no pressure loss in distributor.)
 Shell&Tube Minimum Allowable MTD Ft
Correction Factor
Most of the correction factor curves become very steep below 0.7, which is
why the Aspen Shell&Tube program defaults to 0.7 as the minimum F factor
before going to multiple shells in series in design mode. The only exception is
the X-type shell, where the program allows the F factor to go as low as 0.5 in
design mode. In rating mode, the default is 0.5. With this input item, you can
specify a lower or higher limit.
 Shell&Tube Fouling Calculation Options
Fouling calculations determine the exchanger fouling that would lead to a
specified duty. Some shell side or tube side fouling may be initially specified.
One or both will be updated. The various fouling calculation options are:
· Set default
· Adjust hot side fouling only
· Adjust cold side fouling only
· Adjust both sides based on fouling input
· Adjust both sides using equal fouling
 Shell&Tube Fouling Layer Thickness
Fouling layer thickness may be specified explicitly, or may be deduced from
the fouling resistance and a specified fouling thermal conductivity.
The program calculates the reduction in flow areas due to the fouling layer
and the consequent increase in the tube side or shell side pressure drop. It is
possible that the tube-baffle and shell-baffle leakage paths can get completely
blocked.
The reduction in flow area due to the fouling layer thickness also directly
affects the relevant stream heat transfer coefficients, the heat transfer area
on which the fouling occurs, and the Reynolds numbers. The presence of a
fouling layer of finite thickness may therefore cause changes in the "clean"
heat transfer coefficient reported in the output, though these will normally be
minor, because the effect of the increased mass flux will often be
compensated for by the change in local heat transfer area. If no fouling layer
thickness or thermal conductivity is specified, the effect of fouling on flow
area is ignored, even though its effect on heat transfer is determined.
In fouling calculation mode, if a fouling layer thickness and fouling resistance
are initially specified, these are used to determine a fouling thermal
conductivity, which permits the fouling layer thickness to be recalculated each
time the fouling resistance is adjusted.
The program places an artificial upper limit on fouling thickness, so that
neither tube side nor shell side flow can ever be blocked completely.
 Shell&Tube Fouling Thermal Conductivity
Fouling layer thermal conductivity is used to relate the fouling thickness to
the fouling resistance (fouling factor), so that if one is given, the other can be
calculated.
 Shell&Tube Hot Side Pressure Drop Calculation
Options

Select whether the static head (gravitational) pressure drop may or may not
be included in the overall pressure drop.
 Shell&Tube Cold Side Pressure Drop Calculation
Options

Select whether the static head (gravitational) pressure drop may or may not
be included in the overall pressure drop
 Shell&Tube Vibration Analysis Method
Select which method for Shell&Tube to use for the vibration analysis:
Full HTFS analysis
Simple TEMA analysis
HTFS and TEMA analysis

The Full HTFS analysis determines the tube natural frequency, taking into
account all the tube support locations, and undertakes a sytematic analysis of
vibration effects using appropriate crossflow velocities at points along the
tube length.
The TEMA analysis makes simplifying assumptions based on the longest span
length rather than the entire tube. TEMA vibration results are only output if
specifically requested.

See also:
Vibration Analysis: Overview
 Shell&Tube Tube Axial Stress
Enter a value for axial (longitudinal) stress in the tubes if desired. This item
only affects the Vibration: Natural Frequency. Compressive (negative) axial
stress decreases the natural frequency of a tube; tensile (positive) stress
tends to increase it. For some exchangers the axial stress can have significant
effect on the vibration response.
Axial loads on tubes, either compressive or tensile can arise from:
Pressure differential between shell side and tube side fluids.
Differential thermal expansion between tubes in different passes of a multi-
tube pass exchanger.
Differential thermal expansion between tubes and shell in the case of fixed
tubesheet designs.
Residual stresses induced during manufacture.

Aspen Shell&TubeMech can be used to calculate the axial stress.

U-tube bundles and floating head designs can help to reduce axial stress, but
cannot remove the effects altogether (see notes a & b above).
The axial stress is related to the axial load by: F = S.A
Where:
F= Load
S = Stress
A = Tube metal cross-sectional area
Limitation:
Currently there are no agreed design rules for estimating axial stress in a U-
bend. At present Shell&Tube ignores axial stress effects in a U-bend.

See also:
Vibration Analysis: Overview
 Shell&Tube Effective Cross Flow Fraction
Tube vibration calculations depend on shell side fluid velocities around the
tube. These are calculated using the fraction of the shell side flow which is in
crossflow through the bundle (as against bypassing round the outside of the
bundle or leaking through baffle clearances). Allowance is also made for
sealing strips locally enhancing the crossflow fraction. These crossflow
fractions are calculated at each point along the bundle in order to determine
shell side pressure drops and heat transfer coefficients.
You can specify an Effective Crossflow Fraction to be used in tube vibration
calculations in stead of the standard program calculated values.
 Shell&Tube Single Phase Tube Side Heat
Transfer Method
Two options for single phase in-tube heat transfer are offered, the
recommended HTFS method, and the Hetran method. This second option input
can be useful if you want to achieve consistency with previous Hetran
calculations. The differences in prediction are small except for the extremes of
high and low Reynolds number
HTFS uses the ESDU (1967) correlation of turbulent flow, based on an
extensive review of all the available data. Hetran uses the earlier Dittus-
Boelter correlation. This gives coefficients about 16% higher at Prandtl
numbers close to 1.0 and Re > 20,000 (i.e. gas flows). Difference can be
greater at Prandtl numbers less than 1
ESDU’s review of the data showed that, for Prandtl between 0.32 and 1.0,
Dittus-Boelter overpredicts data, with an rms error larger than ESDU (1967)
Differences at low Reynold’s numbers centre on the way buoyancy is handled
in laminar and transitional flows. This effect is most significant with large
temperature differences. In general Hetran has a lower allowance for
buoyancy than the HTFS recommended method.
For horizontal tubes buoyancy effects always increase coefficients.
For vertical tubes buoyancy can give an increase or decrease in coefficient,
depending on the combination of upflow/downflow and heating/cooling. The
effects can be surprisingly large. The HTFS method can in some circumstances
predict that the coefficient for a vertical upwards flow being heated is
increased by a factor of 5. Large increases of this kind have been confirmed
by experimental data.
 Shell&Tube Low Fin Tube Calculation Method
HTFS / ESDU
Wolverine heat transfer
Rabas et al (SM17)

The default method (HTFS/ESDU) is a correlation of the available data, and is

more accurate then the alternative Rabas et al correlation.
The Rabas et al correlation was applied the Shell&Tube program. It was based
on a smaller databank and generally gives lower heat transfer coefficients. It
is provided here to allow previous results to be replicated.
The Wolverine method is based on a scaling of the plain tube coefficient to the
low-fin surface and flow areas. It generally gives higher heat transfer
coefficients than the HTFS/ESDU method.
 Shell&Tube: Viscosity Method for Two Liquid
Phases
You can select one of five methods for calculating the effective viscosity of
two liquid phases.
· The HTFS selected method (HTFS emulsion for single phase and boiling,
higher viscosity for condensing)
· The HTFS emulsion method
· The HYSYS emulsion method
· Use higher viscosity
· The old HTFS method (the only option in V7.2.1 and earlier)
Since predictions can have significant uncertainty even with the HTFS
selected method, you can use the other methods to understand how much
these uncertainties affect exchanger design.
Usually, a case with two liquid phases involves oil and water, so we will refer
to the higher viscosity liquid as oil, and the lower viscosity liquid as water.
The flow is often in the form of an emulsion, which means droplets of one
phase are carried along by the flow the dominant, continuous phase. The
presence of such droplets can significantly increase the viscosity of the
dominant phase, so effective viscosities higher than either the oil or water
often occur.
When one phase is present in relatively small amounts, the situation is
straightforward, but when the amounts of the phases are comparable,
significant uncertainties can appear. As the amount of oil increases, the
continuous phase eventually changes from water to oil. This change can lead
to a very large increase in effective viscosity.
An emulsion does not always occur. In condensation, the flow is often
filmwise, with one fluid on top of or in parallel with the other. In such cases,
using the higher viscosity is good practice.
The HTFS selected method uses the higher viscosity method for condensing
flows, and the new HTFS emulsion method for single phase and boiling flows.
The old HTFS method is the basic Brinkman method, an emulsion method in
which the effective viscosity of the dominant phase varies inversely as its
volume fraction to the power of 2.5. The lower of the two effective viscosities
is used. An ad hoc viscosity reduction is applied in the (unusual) event of the
effective viscosity being more than twice the higher individual phase viscosity.
The new HTFS recommended method has two improvements. The first is that
there is explicit prediction of the inversion point, which is normally in the
range 0.45 to 0.75 for volume fractions of oil. The higher the oil viscosity, the
higher the inversion point volume fraction. The power used to determine
effective phase viscosity is also lower: it will be relatively close to 2.5 for the
water dominant region but is lower for the oil, falling to near unity for very
high viscosity oil. The region of rapid viscosity change is assumed to occur
over an oil volume fraction range 0.1 below the inversion point.
The HYSYS method does not use a Brinkman type power law equation for
effective viscosity, but the resulting viscosities are broadly similar to using a
power of 2.5. The major difference is that the oil is assumed to be dominant
for oil volume fractions above 0.5, and the water is assumed to be dominant
below 0.33. A weighted mean is used in the transition region.
The option to use the higher viscosity uses the oil viscosity as long as the
volume fraction of oil is above 5%, below which there is a linear transition
down to the pure water value. This method might be more appropriate in
downflow condensation cases or falling film evaporators where there is film
flow rather than droplet flow. It can also be used to avoid uncertainties
associated with being one side or other of a step change near the inversion
point.
Of the three methods for emulsions, the HYSYS method will give the highest
viscosity for oil volume fractions above 0.33. The new HTFS method will give
slightly lower effective viscosities than the old method in the water dominant
region, and somewhat larger reductions in the oil dominant region. The oil
dominant region will however extend to lower oil volume fractions.
Differences between the predictions of the three methods will generally be
larger for heavy oils than for light oils.
A warning message is produced whenever the oil volume fraction is in or near
the transition region for a method. Another message is produced whenever a
predicted viscosity is more than 50% greater than the oil viscosity. Both
messages give the temperature range where these conditions occur. The
range may extend to temperatures beyond that of the bulk fluid, since
viscosities often need to be evaluated at wall temperatures as well as bulk
temperatures.
 Shell&Tube Desuperheating Heat Transfer
Method
The options are:
Set default
Wet wall
Dry wall

Wet wall desuperheating occurs when the bulk temperature of a stream is

above the dew point, but the local wall temperature is below the dew point. If
the wet wall calculation is selected, the program corrects the heat transfer
rate in the desuperheating zone to allow for condensation occurring at the
wall.
When the alternative dry wall calculation is selected the program uses the
single phase gas coefficient until the bulk vapor temperature reaches the dew
point. Usually dry wall coefficients are lower than wet wall coefficients, and
hence more conservative.
The wet wall calculation is the default, and is recommended because it is a
more correct representation of the physical processes.
 Shell&Tube Condensation Heat Transfer Model
The options are:
Set default
HTFS – Mass Transfer
HTFS – Silver-Bell

The Standard method for mixture condensation or condensation from a non-

condensing gas in Shell&Tube is an adaptation by HTFS of the Silver (Bell and
Ghaly) method.
There is an option to use an HTFS adaptation of the Colburn-Hougen method
for condensation of a vapor from a non-condensing gas. This is a mass-
transfer model which requires additional data relating to the diffusion
coefficient, or properties from which it can be calculated. The method is used
with the integral condensing curve which you supply (or which Shell&Tube
calculates). This method as implemented in Shell&Tube will not provide
additional information on the distribution of components between the liquid
and vapor phase.
The Standard condensation method in Shell&Tube does not model the mass
transfer effects explicitly, but incorporates an additional thermal resistance
relating to the vapor phase, which has a comparable effect on the overall heat
transfer.
 Shell&Tube Vapor Shear Heat Transfer
Enhancement
This item allows you to switch off the vapor shear enhancement effect in the
calculation of the shell side condensate heat transfer coefficient. Vapor shear
enhancement leads to increased heat transfer coefficients. It is recommended
that you leave this option switched on (the default). However, if you prefer a
conservative estimate to be used, switch this item off.
 Shell&Tube Liquid Subcooling Heat
Transfer/Vertical
The options are:
Set default
Forced convection
Falling film
Not used

This item applies to condensation in a vertical exchanger. It is most

appropriate to tube side condensing, but can be applied with caution to shell
side condensing.
You can use this item to over-ride the default Shell&Tube methods for
calculating the heat transfer coefficient for condensate cooling in vertical
shells. If you chose the Falling Film, the heat transfer coefficient will be
calculated from methods in which it is assumed that there is everywhere a
thin film of condensate on the surface.
In the Standard Method, a falling film coefficient is usually used for
condensate cooling over the condensing range. For condensate cooling below
the bubble point, it is assumed that the tube runs full of condensate at the
outlet. There is interpolation between a film wise subcooling coefficient at the
bubble point to a "tube runs full" coefficient at the outlet.
The Falling Film option will normally generate higher heat transfer
coefficients than the Standard Method.
It is recommended that you only override the default methods when you are
confident of maintaining a continuous film over the entire tube length.
In vertical exchangers with shell side condensation, there will normally be a
level of liquid determined by the location of the outlet nozzle. This is likely to
make the Standard Method more appropriate.
 Shell&Tube Priority for Condenser Outlet
Temperature (mixtures)
In condensation over a temperature range with partial condensation, it is
possible in practice for the vapor-gas and condensate outlet temperatures to
be different. In the default method in Aspen Shell & Tube Exchanger V7.0,
the calculation determines the surface area required to condense the vapor
and cool the vapor-gas to the specified outlet temperature. Aspen Shell &
Tube Exchanger V7.0 provides a new option in which the calculation is
weighted towards the area required to cool the condensate, rather than the
vapor-gas, to the outlet temperature. This option will usually give higher
overall heat transfer coefficients than the default method, and it is similar to
the method used by the Hetran program. You should only use this new option
when the main objective is to cool the condensate to a specified outlet
temperature.
 Shell&Tube Subcooled Boiling accounted for in
The options are:
Set default
Heat transfer and pressure drop
Heat transfer only
Pressure drop only
Not allowed for

The options above allow you to specify whether or not you want the program
to do calculations of subcooled boiling. This occurs when the wall temperature
in a liquid below its bubble point is high enough to generate vapor bubbles.
Allowing for subcooled boiling will lead to higher heat transfer coefficients and
increased frictional pressure losses, and will modify the gravitational pressure
changes in this region.
The default is to allow for subcooled boiling in both heat transfer and pressure
change calculations.
Note that subcooled boiling can occur when heating liquids, even if the outlet
temperature (mixed mean) is below the bubble point. To ensure that such
subcooled boiling in liquid streams is allowed for their properties should be
specified as two-phase and pressure dependent.
 Shell&Tube Post Dryout Heat Transfer
determined
The options are:
Set default
Yes
No

You may specify whether or not you want the program to do calculations of
post-dryout heat transfer. This will lead to lower heat transfer coefficients
when a two-phase stream being heated has passed the point of critical heat
flux, when dryout occurs.
If you enter "No", the program will calculate normal boiling coefficients in the
region beyond the point of dryout.
 Shell&Tube: Heat Flux Reference Point
If you are providing a User-specified Boiling Curve to be used in calculating
boiling coefficients, specify the heat flux at the reference point used to define
the curve.
The heat flux should relate to the heating surface; it should be based on tube
OD for shell side boiling, or tube ID for tube side boiling.
 Shell&Tube: Temperature Difference (Delta T)
Reference Point
If you are providing a User-specified Boiling Curve to be used in calculating
boiling coefficients, specify the wall to stream temperature difference at the
reference point used to define the curve.
 Shell&Tube: Boiling Curve Exponent on Delta T
If you are providing a User-specified Boiling Curve to be used in calculating
boiling coefficients, specify the exponent on temperature difference used to
define the curve.
 Shell&Tube Correction to Boiling Curve
When you input a boiling curve, you can select how it is used.
The options are:
Set default
No corrections – Use as given, with no corrections for mixture effects or
convective boiling
Mixture + convection - Apply HTFS mixture corrections and convective boiling
terms
Boiling curve not used

Note that boiling curves are normally very specific to particular fluids, tube
surfaces and operating pressures. They generally apply to pure fluids in
nucleate / pool boiling situations, where flow effects (other than those
induced by rising bubbles) are secondary.
‘No corrections’ - This option should only be used when there is a good match
between the conditions in your exchanger and those to which the boiling
curve relates.
‘Mixture + Convection’ - Mixture corrections and convective effects may
permit useful results to be obtained when the match is less good.
 Shell&Tube Falling Film Evaporation Method
The options are:
Program
HTFS recommended method
Chu Seban (Hetran method)

Two options for falling film evaporation are offered, the recommended HTFS
method, and the Chun-Seban method, used in Hetran and elsewhere. This
input can be useful if you want to achieve consistency with previous Hetran
calculations.
The Chun-Seban method is a well known open literature method, based on
data for evaporating single component fluids with a limited range of
properties
The HTFS method uses a correlation developed by Wadekar (Research Report
1046, 1999). It is based on data covering a large range of liquid properties. It
gives significantly lower coefficients than Chun-Seban at liquid Prandtl
numbers greater than about 10.
The HTFS method also incorporates a mixture correction factor based on data
from Lehigh University. This can give significant reduction in coefficient when
there is a long temperature range
Hetran does not have a mixture correction factor for falling film evaporation.
 Shell&Tube: User-specified Boiling Curve
For a boiling stream, you can specify the use of a heat transfer coefficient
based on a boiling curve which you supply. A boiling curve can be applicable
when nucleate boiling dominates and convective boiling is small.
A boiling curve is a relation between heat flux and driving wall to stream
temperature difference. It usually follows the form:
heat flux is proportional to temperature difference raised to some power
greater than unity
To define such a curve, supply one value of temperature difference, the
corresponding heat flux, and power (exponent) to which the temperature
difference is raised. Using this information, the program can calculate the
heat flux that applies at any other temperature difference.
Heat transfer coefficients are equal to heat flux divided by temperature
difference, and so are readily determined using a boiling curve.

See also
Vaporization
Heat Flux Reference Point
Temperature Difference (Delta T) Reference Point
Boiling Curve Exponent on Delta T
 Shell&Tube: Minimum Calculated Pressure

This input assists with cases where the calculated pressure drop is much
higher than anticipated. In extreme cases, the pressure drop might even be
predicted to be bigger than the stream inlet pressure. The program handles
such cases by applying a scaling factor to the calculated pressure changes
before using them to calculate absolute pressures. The scaling is calculated,
when needed, by ensuring that calculated outlet pressure does not fall below
the specified minimum.
When this type of pressure change scaling is applied, a warning message is
produced.
The default value of the minimum calculated pressure is typically three
quarters of the inlet pressure, unless you have explicitly specified an outlet
pressure or a maximum pressure drop, indicating that a lower default
minimum is required.
In versions of the program prior to V7.3, the minimum calculated pressure
was not an explicit input, but was always taken to be the inlet pressure less
the maximum pressure drop. This new input item both gives you more control
on calculated pressure changes and means that the warning about pressure
scaling will occur less frequently.

See also:
Pressure Calculation Option
 Shell&Tube: Checking and Simulation, Pressure

Although the terms Checking and Simulation normally refer to heat loads, it
is also possible by analogy to define Checking and Simulation for pressure
calculations. Conventionally, pressure calculations involve Pressure
Simulation, usually calculation of outlet pressures for a specified inlet.
Pressure Checking involves keeping the inlet and outlet pressures fixed and
calculating a scaling factor which if applied to the calculated pressure change
would give consistency with the specified inlet and outlet pressures. The
pressure at any point within the exchanger is found using the inlet pressure
and the scaled pressure change to that point. There is a further form of
pressure calculation which involves Simulation as long as the outlet pressure
does not fall below a specified minimum pressure but reverts to Checking,
using the inlet and the specified minimum, for higher predicted pressure
changes. This is the default option, since it is “safe” in preventing implausibly
low pressures and concomitant calculation instabilities. When this occurs,
there is a warning that scaled pressure changes have been used to determine
pressures.
Explicit specification of the minimum pressure was introduced in V7.3.2.0.
Prior to that, the minimum used for this purpose was effectively the inlet
pressure less the maximum allowed pressure drop. The default for minimum
is such that warnings about scaled pressure changes will occur less
frequently. Pressure Checking or Simulation and other related options are
available individually for each stream, and each can be used in conjunction
with either a Heat Load Simulation or Heat Load Checking Mode.
 Shell&Tube Heat Transfer Resistance Diagram
The resistance diagram appears at the bottom of the Performances screens.
It shows the thermal resistance between the shell side and tube side streams
broken down into five components along the length of a horizontal bar.
The five resistances are
Shell Side stream
Shell Side fouling
Tube wall
Tube Side fouling
Tube Side stream.
By default, the stream resistances are yellow, the fouling resistances red, and
the wall resistance black.
Resistances are derived from mean heat transfer coefficients.
Thermal resistances are the inverse of heat transfer coefficients.
The Diagram provides an immediate indication of the largest resistance in the
system, which is the one where an improvement would have the greatest
benefit.

Back to:
Overall Performance
Resistance Distribution
 Shell&Tube Vibration Analysis: Overview
When a fluid flows across or past a supported tube it can excite vibration of
the tube. In some cases this flow-induced vibration can be severe and result
in damage of the exchanger. It is therefore important that the possibility of
tube vibration is assessed during the design of shell and tube heat
exchangers.
The tube vibration problem is complicated because it concerns fluid dynamics,
structural dynamics and the mechanical properties of the materials involved.
The phenomenon arises solely from the flow of the shell side fluid across the
tubes and is not associated with other undesirable sources of vibration such
as pump pulsations or mechanically transmitted vibrations from elsewhere in
the plant.

The main mechanisms and factors which influence the Shell&Tube vibration
assessment are:
1. Geometry Factors
2. Natural Frequency
3. Acoustic Resonance
4. Vortex Shedding
5. Turbulent Buffeting
6. The "Lock-In" Effect
7. Damping
8. Fluid-Elastic Instability
The following documents, available to HTFS Research Network members,
describe the vibration calculations in more detail.
DR12 TASC3 Shell & Tube Heat Exchanger Program, Part 1 Section 7 (1993)
DR48 Tube Vibration in Shell & Tube Heat Exchangers (May 1993)
HTFS Handbook Volume 3, Chapter V: Vibration

See also:
Vibration Damage
Avoiding Vibration
Avoiding Vibration - Recommended Practice
Shell Types Considered
 Shell&Tube Vibration: Tube Rows Examined
The risk of vibration depends on how well a tube is supported (for example,
whether it is in the window region or the crossflow overlap region) and on the
flow across it at each point along its length.
Experience has shown that there are certain tube rows within an exchanger
that are most likely to suffer vibration damage. These are basically the
uppermost and lowermost tube rows with respect to the flow and the tube
rows just inside or just above the edge of the baffle cut. Usually one tube in
the row can be taken as representative of the row. These are the tubes
considered in the vibration analysis in Shell&Tube.
It is also possible for you to select any other tube in the exchanger to include
in the vibration analysis. See Vibration Tubes.
The program-selected tubes are given numbers identifying their location.
· Tube 1: window tube immediately under the inlet nozzle
· Tubes 2 and 8: window tubes just outside the baffle cuts
· Tubes 3 and 4: crossflow (baffle overlap) tubes just inside the baffle cut
· Tube 5: on the opposite side of the bundle from Tube 1
· Tube 6: same row as Tube 1, but away from any impingement plate
· Tube 7: within the inner window of double segmental baffles
Tube locations are adapted for different baffle cut orientation, for No-Tubes in
Window exchangers, for U-bends and for X and K-shells. The diagram below
shows the five basic locations. Locations 6, 7, and 8 are new in V7.3.2.0.
Key factors are the extent of tube support and the velocity impacting the
tube. Clearly a tube in the window region of an exchanger is supported by
every other baffle. In the overlap region a tube is potentially supported by
every baffle. This has an important effect on the calculation of, for instance,
tube Natural Frequency and hence the likelihood of vibration.
For the Vibration Resonance analysis, three positions along the exchanger are
considered for each tube. These essentially correspond to the inlet end,
defined by the region between the tubesheet and first baffle; the outlet end,
defined by the region between the last baffle and the other tubesheet; and a
mid-space, defined by a typical region between two baffles. Entry conditions
can be critical to the vibration response of a heat exchanger.
See also:
Entry Conditions
Shell&Tube Double Pipe
Shell&Tube Multi-Tube Hairpin
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Rear Head with Full Diameter Support
Plate at U-Bend

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Front Head with Full Diameter
Support Plate at U-Bend

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Rear Head with Nozzle over U-bends

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Rear Head with Nozzle beyond U-
bends

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Rear Head

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Front Head

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Rear Head with Full Diameter Support
Plate at Floating Head

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Front Head with Full Diameter
Support Plate at Floating Head

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Shell Side Inlet
Nozzle at Rear Head without Full Diameter
Support Plate

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Baffled `F' Shell

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Note: In this case, Sl = Support Plate Thickness as support is located adjacent

to U-bend.

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Unbaffled `F' Shell

Nomenclature
Rw Window Length at Rear Head

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Baffled `G' Shell

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Distance between Baffles at central Shell Side

Cl
Inlet/Outlet Nozzle

Note: In this case, Sl = Support Plate Thickness as support is located adjacent

to U-bend.

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Unbaffled `G' Shell

Nomenclature
Fw Window Length at Front Head

Rw Window Length at Rear Head

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Baffled `H' Shell

Nomenclature
Fl End Length at Front Head

Rl End Length at Rear Head

Baffle Spacing at Inlet (Shell Side Inlet

Bi
Nozzle)

Baffle Spacing at Outlet (Shell Side Outlet

Bo
Nozzle)

B Baffled Region

Length of Tube beyond Support/Blanking

Sl
Baffle

Hl Distance between Baffles at center of H Shell

Distance between Baffles at central Shell Side

Cl
Inlet/Outlet Nozzle

Note: In this case, Sl = Support Plate Thickness as support is located adjacent

to U-bend.

Back to:
Shell and Tube Geometry - Bundle Geometry
 Shell and Tube Geometry Unbaffled `H' Shell

Nomenclature
Fw Window Length at Front Head

Cw Window Length at Center

Rw Window Length at Rear Head

Back to:
Shell and Tube Geometry - Bundle Geometry
 AirCooled: Program Calculation Mode
Design with fixed outside flow
In design mode, you specify the performance requirements in terms of inlet
and outlet process conditions. The program searches for a satisfactory heat
exchanger configuration by varying the tubes per bundle, the tube rows deep,
the tube length, the tube passes, the bundles per bay, the bays per unit and
the fans per bay.
Design with varying outside flow
In design mode, you specify the performance requirements in terms of inlet
and outlet process conditions on the tube side and the inlet temperature on
the outside of the tubes. The program will vary the outside flow and
determine the required outlet temperature for that flow. For each flow, the
program searches for a satisfactory heat exchanger configuration by varying
the tubes per bundle, the tube rows deep, the tube length, the tube passes,
the bundles per bay, the bays per unit and the fans per bay. The final
optimized solution will be slected based on capital cost of the equipment or
the combined capital and operating cost. The user can control the flow and
cost optimization using parameters located in the optimization options form.
Rating / Checking
In rating mode, you specify the performance requirements in terms of inlet
and outlet process conditions and the specific heat exchanger configuration.
The program checks to see if that heat exchanger is adequate to meet the
required heat exchange and maximum pressure drop requirements.
Simulation
In simulation mode, you specify the specific heat exchanger configuration and
some combination of stream process conditions. The program will predict one
or more of the unknown conditions of the two streams. There are nine
different simulation options for AirCooled.
 AirCooled: Select Geometry Based on this
Dimensional Standard
The dimensional standard used for selection of vessel thicknesses, tube
lengths, nozzle sizes will vary with where the unit may be fabricated or put
into service. In the U.S., it is typical to use 0.0625" increments for vessel
thicknesses whereas in EU 1 mm is typical. This input allows the program to
select equipment dimensions that are relevant to the equipment being
designed and built.
 AirCooled: Tube side application
Program
The phase of the tube side process stream is unknown for the desired
temperature and operating pressure range, the program will determine the
phase or phase change when the stream physical properties are retrieved
from one of the properties databanks.
Liquid, no phase change
The stream is a liquid and not changing phase or you wish to force the
program to treat it as a liquid with no change of phase.
Gas, no phase change
The stream is a gas and not changing phase or you wish to force the program
to treat it as a gas with no change of phase
Phase change
The stream is condensing or vaporizing over the desired temperature and
operating pressure range. If, however, the physical properties specified or
retrieved from the physical properties databanks do not reflect a change of
phase over the operating conditions ranges, the program can only treat the
stream as a single phase application.
 AirCooled: Outside tube application
Dry Air
Dry Air is appropriate for air-cooled heat exchangers and other heat
exchangers where air is being heated.
Humid Air
Humid Air should be chosen for air-conditioning equipment and turbocharger
intercoolers where humid air is being cooled.
Gas (properties specified or from Databank)
Dry Gas is appropriate for waste heat recovery units where gases such as flue
gases are being cooled. Also for any exchanger where gases other than or
including air are handled. It should be noted that AirCooled cannot handle
condensation of any of the components of the gas stream. However, if
condensable components are defined then warnings will be issued if there is
any likelihood of condensation occurring on the surface or in the bulk stream.
When a gas is specified, the user has to supply properties through the normal
Physical Properties input.
 AirCooled: Simulation calculation
1) Outlet temperatures on both sides (method 1)
Calculates the tube side and X-side outlet temperatures from the tube side
inlet pressure, temperature & flowrate, and the X-side inlet temperature and
flowrate. Similar to the outside temperatures on both sides (method 2), but
uses a combined forward and backward iteration technique and so will be
slightly more accurate and may reach a converged solution quicker
2) Process inlet and X-side outlet temperatures
Calculates the tube side inlet temperature and X-side outlet temperature from
the tube side outlet pressure, temperature & flowrate, and the X-side inlet
temperature and flowrate. The tube side outlet pressure is calculated from the
tube side inlet pressure and the estimated pressure drop.
3) Outlet temperatures on both sides, and X-side flow (natural
convection)
Calculates both side outlet temperatures and the X-side flowrate during
natural convection. Can be used when all fans in an air-cooled heat
exchanger are switched off.
4) Process flow and X-side outlet temperature
Calculates the tube side flowrate and X-side outlet temperature from the tube
side stream inlet temperature and desired outlet temperature and the X-side
inlet temperature and flowrate.
5) X-side flow and X-side outlet temperature
Calculates the X-side flowrate and X-side outlet temperature from the tube
side stream inlet and outlet temperatures and flowrate and the X-side inlet
temperature.
6) Process fouling resistance and X-side outlet temperature
Calculates a hypothetical tube side fouling resistance and X-side outlet
temperature to give a process duty that matches the duty calculated from the
input tube side conditions. This gives an indication on the surplus heat
transfer surface area available.
7) Outlet temperatures on both sides (X-side flow given as velocity)
Calculates the outlet temperatures on both sides and the X-side flowrate from
an input value of the bundle face velocity (see Process Data form - Outside
stream tab - Requried face velocity input form), which is then used in
Standard Simulation.
8) Outlet temperatures on both sides (X-side flow estimated from
pressure drop)
Calculates the outlet temperatures on both sides and the X-side flowrate from
an input value of the bundle pressure drop (see Process Data form - Outside
stream tab - Requried bundle pressure drop input form), which is then used in
Standard Simulation.
9) Outlet temperatures on both sides (method 2)
Calculates the tube side and X-side outlet temperatures from the tube side
inlet pressure, temperature & flowrate, and the X-side inlet temperature and
flowrate. Similar to the outside temperatures on both sides (method 1), but
uses a purely forward iteration technique and so will be slightly less accurate
and may reach a converged solution longer.
 AirCooled: Equipment Type
In addition to a conventional air cooled heat exchanger, AirCooled can model
a simple bundle in a duct, which transfers heat to or from a specified flow of
air or other gas flowing over the bundle.
If you select Ducted Bundle, the input is simplified; irrelevant items (such as
those relating to fans) are greyed out.
 AirCooled: Multiple Services in Bay
You can use Aspen AirCooled to assist in modeling an air cooler in which a fan
bay contains two or more different services. The diagram illustrates an
example in which three different services share the same fans and plenum.

Aspen AirCooled can be used to model each service separately. It will allow
for the plenum width being greater than the width of each of the tube
bundles, and for the different air flowrates over each tube bundle. Note that
you need to set up a separate AirCooled EDR file for each service.
This option requires two additional inputs:
· Flow Fraction of Air: Enter the fraction of the air flowrate that
corresponds to the Process Data for the service defined in the data file.
· Bay Width: Enter the width of the bay that contains the multiple
services.
AirCooled uses the input total air flowrate in all calculations associated with
the fan and plenum. It uses the total air flowrate and the input air flow
fraction to calculate pressure loss and heat transfer over the tube bundle.
To apply AirCooled to multiple services in a bay:
1. Set up separate .EDR files for each service.
2. Select Yes for Multiple Services in Bay in the Applications form.
3. Enter the same total air flowrate in the Process Data in all files.
4. Enter the fraction of the air for each service in the appropriate file. The
fractions must sum to unity.
5. Enter a bay width in all files that is consistent with the sum of the tube
bundle widths.
6. Run each file separately.
7. Examine the airside tube bundle pressure drops. You should adjust the
input air flow fractions and re-run the files until the calculated airside pressure
drops are equal within a reasonable tolerance.
AspenTech plans to provide an Excel spreadsheet to perform the iterative
calculations required in Step 7.
 AirCooled: Fluid name
Enter a fluid name which will appear on the API specification sheet.
 AirCooled: Mass flow rate (total)
You should normally enter the total mass flow rate for each stream. If you are
using either the Tube Side Flow rate or the X-side Flow rate Simulation
Options, you should still enter a value which AirCooled will use as a starting
point.
A mass flow rate may be omitted if sufficient inlet, outlet temperatures, flow
rates, or heat loads are specified to allow the program to perform an energy
balance and calculate it.
 AirCooled: Temperature
Enter the tube side stream inlet and outlet temperatures. In Simulation
mode, you do not need to enter a temperature that is to be calculated in the
simulation. The outlet temperature can also be omitted if the sufficient
temperatures, flows, and/or heat loads are specified to permit a heat load
balance to be performed.
If a specified inlet temperature and inlet vapor fraction are inconsistent with
stream physical property data, then the program selects one of the values and
modifies the other.
Note: In Design and Checking modes, the specified outlet conditions are set
on the basis of the inlet pressure minus the estimated pressure drop. Thus,
with a two-phase tube side stream, the heat load used for the design or
checking calculation is influenced by the estimated pressure drop. The final
results can therefore show slightly different outlet conditions from those
specified if the calculated pressure drop is different from the estimated
pressure drop. The difference could be significant in low pressure cases with
phase change, where local vapor-liquid equilibrium conditions are strongly
affected by the local pressure.
 AirCooled: Vapor mass fraction
Enter the mass quality (vapor fraction) at the inlet for the tube side stream
only. The X-side stream mass quality is assumed to be 1.0.
If this item is omitted, it will be calculated from the specified inlet
temperature and pressure, if possible. If however the stream is a boiling or
condensing single component at inlet, then the inlet quality must be specified.
If no inlet temperature is specified, for a two phase stream, then an inlet
quality of 0.0 is taken to indicate the bubble point, and 1.0 the dew point.
If both inlet quality and temperature are specified, and they are not
completely consistent with the physical property data you have supplied (or
have asked to be calculated from component data) then either the quality or
temperature will be amended to achieve consistency.
 AirCooled: Operating pressure (absolute)
Enter the absolute pressure of the stream at inlet to the exchanger.
For the Tube side Inlet Temperature Simulation Option the tube side outlet
pressure used as the starting point in the calculation is determined from:
(Inlet Pressure – Estimated Pressure Drop).
 AirCooled: Heat exchanged
You may enter the heat load directly, or omit it and leave AirCooled to
calculate it from the stream flow rate and inlet and outlet conditions.
AirCooled will use the input heat load to calculate the duty ratio (heat load
calculated/heat load input), otherwise it will use the input tube side stream
conditions.
 AirCooled: Estimated pressure drop
Enter a value for the estimated pressure drop. (Include pressure drop through
tubes, nozzles, and headers). This is used only for initial property
calculations. The pressure ratio (i.e. calculated/allowable) is given in the
AirCooled Summary Screen.
No allowance is made for gravitational changes due to changes in vertical
height in the nozzles.
A mean pressure, based on the inlet pressure minus half the estimated
pressure drop, will be used as a default for physical property calculations if
you do not specify a pressure in the Physical Properties input.
The stream outlet pressure will be initially estimated as the inlet pressure
minus the estimated pressure drop. This estimated outlet pressure is used in
the initial heat balance calculations. If you have not specified the stream heat
load explicitly, then the calculated heat load may depend slightly on the
estimated pressure drop.
For the Tube side Inlet Temperature Simulation Option, this item is used in
conjunction with the Tube side Inlet Pressure to determine the Tube side
Outlet Pressure. This is the starting point for the backward iteration, which
this option uses. Therefore, an accurate estimate of the pressure drop is
required. This can be achieved by running AirCooled a few times, using the
calculated value of the pressure drop from a run as the estimated value in the
next run, until the calculated value between runs converge to a few per cent.
Defaults to 10% of Inlet Pressure.
Note: Try to estimate a reasonably accurate value for this parameter
especially for condensers where the actual pressure drop may be low. The
default value may give a system pressure, which is not consistent with to the
actual performance of the unit.
Note: In Design and Checking modes, the specified outlet conditions are set
on the basis of the inlet pressure minus the estimated pressure drop. Thus,
with a two-phase tube side stream, the heat load used for the design or
checking calculation is influenced by the estimated pressure drop. The final
results can therefore show slightly different outlet conditions from those
specified if the calculated pressure drop is different from the estimated
pressure drop. The difference could be significant in low pressure cases with
phase change, where local vapor-liquid equilibrium conditions are strongly
affected by the local pressure.
 AirCooled: Allowable pressure drop
For Design mode only, enter the maximum allowable tube side pressure drop
through the tubes.
This value is used as a design constraint to produce an equipment design and
should include nozzle and header pressure losses.
Default value = 0.2 bar (2.9 psi, 0.204 kgf/cm2)
 AirCooled: Fouling resistance
In AirCooled the fouling resistance on the tube side can be specified as a
function of velocity, temperature, length or phase.
For velocity, temperature and length, you need to specify 3 values of the
parameter and corresponding values of the fouling resistance.
Temperature is the bulk temperature of the fluid.
Length means the distance traveled by the tube side fluid, so the maximum
value will by the tube length times the number of passes.
AirCooled will carry out a linear interpolation between 2 of the points to get
the resistance at each local condition.
For fouling as function of phase you need to input the resistance for each
phase which the fluid can be in (i.e. liquid, 2-phase or vapor).
Note:
1) Tube Side Fouling Resistance is based on the inside diameter of the tubes.
2) Outside Fouling Resistance is based on the outside diameter of the tubes
(not finned area).

See also:
TEMA Fouling Resistances
 AirCooled: Air/Gas mass flow rate
You should normally enter the total mass flow rate for each stream. If you are
using either the Tube side Flow rate or the X-side Flow rate Simulation
Options, you should still enter a value which AirCooled will use as a starting
point.
This item must be entered even if a component composition has been
specified. The composition values will be normalized and there is no
requirement that they should summate to the total flow rate.
In design mode, the total mass flow of the X-side stream will be calculated but
you must enter the total mass flow of the tube side stream.
 AirCooled: Required face velocity
Enter the X-side bundle face velocity (at actual conditions) required when
Simulation Option has been selected. AirCooled will calculate an X-side mass
flow rate consistent with the given value.
 AirCooled: Required bundle pressure drop
Enter the X-side bundle pressure drop (at actual conditions) required when
Simulation Option has been selected. AirCooled will calculate an X-side mass
flow rate consistent with the given value.
Default value: 50 Pa (0.2 in H20, 5.1 mm H20) per row.
 AirCooled: Air/Gas dry bulb design temperature
Enter a value for the inlet dry bulb exchanger design temperature.
This is the temperature of the incoming air and it is a crucial value in design
of air-cooled heat exchangers as it has a significant effect on the overall heat
transfer area required.
It might be the air temperature that is only exceeded on average on a certain
number of hours per year. This is a useful parameter for helping to determine
Annual Fan Power Consumption.
No default value.
 AirCooled: Minimum ambient temperature
Enter a value for the X-side Stream Winter Inlet Temperature (or Minimum
Ambient Temperature).
Note: This is used for calculating maximum fan power consumption only.
Standard Design practice is to size the fan based on the highest volume flow
of air and the highest air density which occurs in the winter.
Only relevant to forced draught exchangers.
Default value = 0°C (32°F)
 AirCooled: Operating pressure specification
The operating pressure for the outside tube stream can be specified in either
of two ways:
· Altitude and Gauge Pressure
· Absolute Operating Pressure
When Altitude and Gauge Pressure is specified, the program uses the
altitude to determine the atmospheric pressure at that altitude and then adds
the specified gauge pressure to determine the absolute operating pressure of
the stream. Otherwise, the user must specify the absolute operating pressure
directly.
In the case of Air Coolers in which a fan is generating a specific head pressure
(gauge pressure) to drive the air across the exchanger, it may only be
necessary to specify an altitude and the program will select a fan which can
develop sufficient head to drive the specified air flow across the bundle.
The absolute operating pressure of the stream is used to determine the
physical properties of the stream.
 AirCooled: Altitude above sea level
Enter the height of the unit above sea level.
Use either or both inlet gauge pressure and altitude to specify the actual inlet
air pressure.
The default air pressure is the International Standard Atmosphere at sea
level, 1.013 bar.
 AirCooled: Inlet pressure (gauge)
Enter the gauge pressure of the air stream at entry to the bundle.
This item is intended primarily for ducted systems where there may be a
slight positive air inlet pressure. Negative values may also be used.
The default air pressure is the International Standard Atmosphere at sea
level, 1.013 bar.
Use either or both inlet gauge pressure and altitude to specify the actual inlet
air pressure.
 AirCooled: Inlet pressure (absolute)
Enter the absolute pressure of the air stream at inlet to the exchanger.
For air on the outside, the absolute pressure is calculated from the air stream
conditions.
 AirCooled: Inlet humidity parameter
Enter a value of the air inlet humidity in the way selected by the Inlet
Humidity Parameter.
Select the way in which the Inlet Humidity Value will be expressed:
Humidity ratio (default)
Defined as the mass of water vapor per unit mass of dry air.
Relative humidity
Defined as the percentage ratio of the actual water vapor pressure to the
water vapor pressure at saturation.
Note that the only two-phase system, which AirCooled can handle on the X-
side, is the condensation of water vapor from a humid air stream.
Important note: If you want to use this parameter, ensure that you have
selected Humid Air for the X-side Option in the Start-up Screen.
 AirCooled: Humidity ratio
Defined as the mass of water vapor per unit mass of dry air.
 AirCooled: Relative humidity (%)
Defined as the percentage ratio of the actual water vapor pressure to the
water vapor pressure at saturation.
 AirCooled: Flow Fraction of Air
When you are modeling just one of multiple services in a bay, specify the
fraction of the air flow which goes over the tubes which you are modeling.
The fraction of the bundle cross section occupied by this service is normally a
good initial approximation. If you are modeling all the services (each needs a
separate EDR file) then you can adjust the flow fractions to give the same
airside pressure drop in each.
See also:
Multiple Services in Bay
 AirCooled: Fouling option
The following options can be selected:
Constant resistance – Constant fouling resistance for stream (this is the
simplest and conventional way of tackling fouling)
Use thermal conductivity and thickness – Constant fouling resistance for
stream calculated from fouling layer thermal conductivity and thickness
Use default curves – Fouling resistance obtained from default curves
Function of velocity – Fouling as a function of stream velocity – 3 fouling
resistance versus velocity points (single phase streams only)
Function of temperature – Fouling as a function of temperature – 3 fouling
resistance versus temperature points
Function of quality – Fouling as a function of stream quality – 3 fouling
resistance versus quality points (two phase streams only)
Function of length – Fouling as a function of distance through the
exchanger – 3 fouling resistance versus length points
Function of stream phase – Fouling as a function of stream phase – Fouling
resistance for liquid, gas and two phase zones

See also:
TEMA Fouling Resistances
 AirCooled: Fouling thermal conductivity
This input becomes available when the Fouling Option of Use thermal
conductivity and thickness has been selected.
Enter a value for the thermal conductivity of the fouling layer.
Note 1: If the value is entered the thermal resistance of the fouling layer will
be included in the heat transfer calculations.
Note 2: Use this item in conjunction with Fouling Thickness and omit Fouling
Thermal Resistance.
 AirCooled: Fouling thickness
This input becomes available when the Fouling Option of ‘Use thermal
conductivity and thickness’ has been selected.
Enter a value for the thickness of the fouling layer.
Default value will depend on the fouling option selected.
Note: Use this item in conjunction with Fouling Thermal Conductivity and
omit Fouling Thermal Resistance.
AirCooled: Include fouling effect in heat
transfer and pressure drop calculation
 AirCooled: Fouling fluid curve group
This input becomes available when the Fouling Option of ‘Use default curves’
has been selected.
 AirCooled: Fouling curve
This input becomes available when the Fouling Option of ‘Use default curves’
has been selected.
Permissible inputs are 1, 2, 3, or 4.
 AirCooled: Fouling resistance by phase
These inputs for Liquid, Vapor and Water become available when the Fouling
Option of ‘Function of stream phase’ has been selected.
 AirCooled: Velocity
These inputs become available when the Fouling Option of ‘Function of
velocity’ has been selected.
 AirCooled: Temperature
These inputs become available when the Fouling Option of ‘Function of
temperature’ has been selected.
 AirCooled: Quality
These inputs become available when the Fouling Option of ‘Function of
quality’ has been selected.
Enter the quality (vapor mass fraction) of the stream corresponding to
temperature Tn
The vapor mass fraction includes both condensable vapors and non-
condensables.
Enter 0 for the liquid region, up to and including the bubble point, and 1 for
the dew point and the vapor region.
Qualities are not needed for single phase streams, but if input are checked to
have the correct value. For two phase streams, qualities should be input if
available. If values between the dew and bubble points are not known, they
may be omitted and will be estimated from the stream enthalpies.
 AirCooled: Length
These inputs become available when the Fouling Option of ‘Function of length’
has been selected.
 AirCooled: Fouling thickness 1
Enter a first value for the thickness of the fouling layer on the base and
extended surfaces.
Note 1: The fouling layer thickness will be constant up to the row specified in
Last Row for Fouling Thickness 1.
Note 2: This fouling affects the X-side pressure drop.
 AirCooled: Last row for fouling thickness 1
Fouling will be constant at Fouling Thickness 1 up to the row number entered
here.
Note: If a value is entered for Fouling Thickness 1 and no value is entered
here then the fouling thickness will be constant over the whole bundle.
 AirCooled: Fouling thickness 2
Enter a second value for the thickness of the fouling layer on the base and
extended surfaces, if applicable. See Fouling on the X-side.
Note 1: Constant fouling at this thickness starts at the row number specified
in First Row for Fouling Thickness 2
Note 2: Fouling thickness is linearly interpolated for the rows between the
Last Row for Fouling Thickness 1 and the First Row for Fouling Thickness 2.
Note 3: If Fouling Thickness 1 ends on row 1, and Fouling Thickness 2 begins
on the last row of the bundle then the fouling thickness will be different for
every tube row.
 AirCooled: First row for fouling thickness 2
Enter a second value for the thickness of the fouling layer on the base and
extended surfaces, if applicable. See Fouling on the X-side.
Note 1: Constant fouling at this thickness starts at the row number specified
in First Row for Fouling Thickness 2
Note 2: Fouling thickness is linearly interpolated for the rows between the
Last Row for Fouling Thickness 1 and the First Row for Fouling Thickness 2.
Note 3: If Fouling Thickness 1 ends on row 1, and Fouling Thickness 2 begins
on the last row of the bundle then the fouling thickness will be different for
every tube row.
 AirCooled: Fouling thermal conductivity
Enter the thermal conductivity of the X-side fouling layer.
Note 1: If a value is entered for this item then the thermal resistance of the
X-side fouling layer will be included in the heat transfer calculation.
Note 2: Use this item in conjunction with Fouling Thickness 1, Last Row
Number for Fouling Thickness 1, Fouling Thickness 2 & First Row for Fouling
Thickness 2, and omit Fouling Thermal Resistance.
 AirCooled: Bays per unit
Enter the number of bays per unit. The default value is 1.
 AirCooled: Bundles per bay
Enter the number of bundles per bay. The default value is 1.
 AirCooled: Fans per bay
Enter the number of fans per bay. The default values are:
· 2 for Air-cooled Heat Exchangers
· 0 for Other Cross flow Types
·
 AirCooled: Fan Diameter
This is the diameter of the fan ring.
The thickness of the fan ring material and the fan tip clearance are ignored.

Note:
Minimum Permitted 100 mm (3.9 Inches)
Maximum Permitted 15000 mm (590.6 Inches)
 AirCooled: Exchanger frame type
None
A or V frame

A and V frames are usually used for condensing duties where good
condensate drainage is obtained. However, they can be used for single-phase
cooling where plot area is at a premium.
To model this type of unit:
1) On the Start-up form, ensure Application is set to ACHE
2) On the Unit Configuration page of the ACHE Geometry input form
a) enter an even Number of Bundles per Bay
b) select A or V frame
c) set Fan Configuration to Forced Draught for an A Frame or Induced
Draught for a V Frame
3) On the Bundle Setup page of the Bundle Geometry input form
a) set the X-side Stream Mass Flow Direction to the inclination angle of the
bundle from the horizontal (see example shown where the angle is set to 60
degrees)
Note that for an A or V frame the yaw angle may be defined as the bundle
inclination angle from the vertical. If that is the case, the X-side Stream Mass
Flow Direction is (90 – yaw angle).
b) set the Bundle Relative Direction to –90 for down--flow in the first pass.
(Note: Reflux Condensation currently cannot be modeled by AirCooled
4) Enter the rest of the geometric, process and physical property data as
normal
5) Save your data to a file and then run the case
 AirCooled: Tube side to outside flow orientation
When there is more than one tubepass, you can specify the overall sequence
of flow through the tube side passes, relative to the X-side flow:
· Counter-current - the tube side flow enters the bundle in the tube
row(s) nearest the X-side outlet
· Co-current- the tube side flow enters the bundle in the tube row(s)
nearest the X-side inlet
Tube rows are numbered in the direction of X-side flow, so counter-current
flow enters row N and leaves row 1, while co-current flow enters row 1 and
leaves row N.
A third option [1-pass crossflow] is obsolete, since this input item is only
needed when there is more than one tube side pass.
This item is used for setting up a standard symmetrical bundle, using input
values for number of rows, passes etc. It is not needed for non-symmetric
bundles, when the pass number of each tube is user-defined using the Pass
Layout Window.
 AirCooled: Fan configuration
Set default
Forced
Induced
No fans
This can be either forced draught where the fans blow air through the tube
bundles or induced draught where the air is sucked through the bundles or
no-fans used.
AirCooled: Tube OD/ID
 AirCooled: Tube wall thickness
The economic choice of tube thickness is the minimum required to withstand
the tube side design pressure.
Rather than calculate this for every single case, design engineers prefer to
use standard minimum values which, for the pressures and temperatures
associated with most exchanger duties, tend to be conservative. TEMA section
'C' gives recommended thicknesses which are more than adequate for most
applications. For high pressures and/or temperature, it is necessary to check
whether the selected tube thickness is adequate. TEMA also gives the
maximum allowable internal pressure for tubes at various values of allowable
stress. This last property, which decreases with increasing temperature, can
be obtained from the relevant code. For high pressure on the outside of tubes,
there is, unfortunately, no short-cut method for determining the minimum
tube thickness and reference must be made to recognized pressure vessel
code.
When ordering tubes, it is necessary to state whether the specified wall
thickness is the average or the minimum required. This distinction is not
usually considered to be significant as far as thermal design is concerned.
When tubes are bent to form U-tubes, the thickness of the tube in the region
of the bend is reduced and it might be necessary, especially at higher
pressures and temperatures, to use tubes that are thicker than normal,
particularly for the inner U-bends. TEMA R-2.31 gives further details.
 AirCooled: Tube length
Enter the total length of tube including the ends fitted into the tubesheets
and where the tube comes into contact with tube supports.
This input item is only used for tube side pressure drop and exchanger weight
calculations.

The default value is obtained from the Effective tube length.

 AirCooled: Fin type
Integral
The fin and tube are formed from one solid length of material. For materials
such as Aluminum or cooper, the fins are extruded from the surface of a
thick-walled tube. For high temperature applications the finned tube may be
machined or cast.
G-fin (embedded) (default)
These fins are formed from metal strip that is tension wound into helical
groove in the base tube. The sides of the grooves are then peened over to
produce a firm mechanical bond. This is a high conductivity fin tube for high
temperature applications up to 450°C.
Modified G-fin
Depending on the fin profile, embedded fins are known as G fins or modified G
fins. AirCooled treats them essentially the same.
L-finned
Economically produced fin tube for moderate working temperatures up to
150°C. ‘L’ Fins rely on maximum surface contact between the fin and the tube
surface by tension winding fin strip helically around the base tube. A high
degree of protection is given to the tube by the foot at the fin base.
Bi-metallic or extruded
In this type, a tube of the fin material is slid over the base tube. The fin is
then extruded from the outer tube. The advantage of this type is that the
base can be selected to handle the tube side fluid chemical properties and
pressure, and the fin material can be selected for good thermal conductivity,
ease of manufacture and atmospheric corrosion resistance. A common
combination of materials is aluminium fining on a mild steel base tube.
Maximum operating temperature 250°C.
Shoulder-grooved
This is a combination of L foot and embedded fins.
Tube-in-plate
Plain tubes
Serrated fins
Low fins
Integral fin tube produced by form rolling from a plain thick wall tube. The
rolling process forms a high strength fin with the plain ends remaining in the
original condition suitable for fixing into headers
Circular studs
Rectangular studs
Elliptical studs
Lenticular studs
Chamfered studs
 AirCooled: Fin tip diameter
For a finned tube, enter the fin tip diameter.
Defaults:
· 2.25 times Tube OD for Air-cooled Heat Exchangers
· 2 times Tube OD for Other Crossflow Types
· Other tube types default to Tube Type 1.
For tube-in-plate fins, enter the plate length in the direction of the X-side
flow (from the leading edge to the trailing edge of the plate). This will be
calculated if left blank.
 AirCooled: Fin frequency
Enter the number of fins per unit length.
 AirCooled: Mean fin thickness
Enter the mean fin thickness. For fins made by wrapping ribbon around the
base tube, the fin thickness is usually thinner than the ribbon thickness.
Defaults:
· 0.28mm (0.011in) for Air-cooled Heat Exchangers
· 1.5mm (0.06in) for Other Crossflow Types
· Other tube types default to Tube Type 1.
An approximation for the mean fin thickness, s, is:
s=D.t
----------
(D + H)

Where,
D is the base tube diameter
t is the ribbon thickness
H is the fin height.
Note: Tapered fins are treated as rectangular with thickness equal to the
mean thickness of the tapered fin.
 AirCooled: Number of tubes per bundle
Enter the total number of tubes in the bundle.
This number is used to check the consistency of the other entries specifying
the tube and pass arrangement.
There is no default value.
 AirCooled: Tube rows deep
Enter the number of rows in the bundle.
In design mode, you must specify the number of rows at the start. AirCooled
will calculate the X-side mass flow required to achieve the given X-side
pressure drop for the specified number of rows. When using the Design
Envelope, you can change the number of rows to create a new envelope.
In all multi-pass condensers and boilers where there is more than one tube
row per pass, separation of the liquid and vapor phases is likely in the return
headers.
In low pressure applications, condensers with more than one row per pass can
suffer from gas blanketing where incondensable gases collect in one or more
of the rows.
There is no default value.
 AirCooled: Tube passes
Enter the number of tube side passes in the bundle.
With four or more passes the exchanger tends towards the ideal of a pure
counter-current or co-current exchanger.
This input is not required in Design mode, and there is no default value.
 AirCooled: Tube rows per pass
Enter the number of tube rows occupied by each tube side pass.
Only to be used when specifying symmetrical bundles. When specifying non-
symmetrical bundles use the Pass Layout Window to specify the bundle
Default: No default value.
 AirCooled: Maximum number tubes per row per
pass
Enter the maximum number of tubes in each row occupied by each pass.
Note 1: Only to be used when specifying symmetrical bundles. When
specifying non-symmetrical bundles use the interactive bundle specification
feature.
Default: No default value.
 AirCooled: Tube layout type
This input determines how the tube layout will be generated:
· Program will design tube layout based on input above
· Use interactive graphical layout to define tube layout
 AirCooled: Bundle type
Inline
Staggered - even rows to right
Staggered - even rows to left
Staggered - extra tubes in odd rows
Staggered - extra tubes in even rows
 AirCooled: Transverse pitch
Enter the transverse pitch of the tubes, that is, the distance between the
centre-lines of consecutive tubes in the same tube row.

Defaults
2.3 times Tube OD for Air-cooled Heat Exchangers
2.5 times Tube OD for Other Crossflow Types
 AirCooled: Longitudinal pitch
Enter the longitudinal pitch of the tubes.
If you have a standard TEMA tube layout, i.e. triangular (30°), rotated square
(45°), rotated triangular (60°) or square (90°) then use the layout angle.
If you have a non-standard tube layout then use this item.
The plain tube correlations are only valid for the standard TEMA tube layout
given above so use layout angle in this case.
Note: For uncommonly large longitudinal pitches, you may have to allow for a
reduction in the heat transfer coefficient separately from AirCooled. Currently
AirCooled does not allow for this effect.
There is no default value. The value will be calculated from the Transverse
Tube Pitch and the Layout Angle.
 AirCooled: Tube layout angle
The fin geometry will have a strong influence on the tube pitch and layout.

Air-cooled heat exchangers

Much greater flexibility is exercised here than in shell and tube exchanger
practice. The minimum pitch is arranged to give a minimum gap > 3mm
between adjacent fin tips. The common TEMA pitch arrangements are used:
Triangular (or staggered): 30 degree layout is common.
Square (in-line): 90 degree possible but seldom used with finned tubes

A common arrangement would be 25.4mm (1 inch) od tubes with fins of

57mm (2.25 inch) diameter attached, arranged on a 60mm (~2.375 inch)
transverse pitch.

Because the fin pitch is relatively large, pass partitions can usually be
accommodated between standard tube pitches. In some instances, wide
pitching between rows may be required.

Note: For uncommonly large longitudinal pitches, you may have to allow for a
reduction in the heat transfer coefficient separately from AirCooled. Currently
AirCooled does not allow for this effect.
 AirCooled: Number of Circuits
Enter the number of times a basic pass layout pattern appears in the bundle.
The repeat facility is used when a basic pass layout pattern is to be repeated a
number of times across the bundle. This feature is most likely to be of use in
air-conditioning coils with U tube circuits. It may only be used:
a) With inline bundles and staggered bundles with the same number of tubes
per row or,
b) When X-side stream inlet conditions do not vary across the bundle.
When using the repeat facility, count the original section as 1 (Default)
 AirCooled: Number of sides fan draws air from
Normally, AirCooled will determine the number of sides from which a fan can
draw air and this is used in the calculation of the ground clearance pressure
drop on the X-side. For example, a single fan can draw air from all 4 sides as
shown in Figure 1, but with 2 fans, the number of sides each fan can draw
from is reduced to 3, as shown in Figure 2. AirCooled will always consider the
worst case, so if the fans in an exchanger can draw from a different number
of sides, the fan which draws from the least number will be used in the
calculation of the ground clearance pressure drop.
You may overwrite the AirCooled value with a value entered here, if you wish
to take account of obstructions such as windshields. So for a single fan you
can enter 3 to take account of a windshield along one side as shown in Figure
3. Note that if you enter a value you should consider the worst case. For 3
fans with a windshield along one side of the exchanger the least number of
sides from which a fan draws air is 1 as shown in Figure 4...
Check the Ground Clearance Pressure Drop in the X-side Pressure Drops
section of the Line Printer output or under Graphical Results from the Output
menu.
 AirCooled: Angle of outside flow
Enter an angle in the range 0° to 180°.
A value of 0° is vertically upwards, 90° is horizontal and 180° is vertically
downwards.
A conventional air-cooled heat exchanger usually has the air flowing vertically
upwards, i.e. the default value of 0°.
A ducted air-conditioning unit will often have air flowing through the coil in
the horizontal direction; i.e. the angle is 90°.
To define an A-Frame Condenser with an angle of 45° to the horizontal, then
set this item to 45°. You will then have to set the Bundle Relative Direction to
+90° if you require the tube side flow in the first pass to be upwards or -90°
if you require the tube side flow in the first pass to be downwards. (Note that
AirCooled cannot currently handle reflux condensation)
 AirCooled: Tube side direction
Horizontal
Upward (any angle)
Downward (any angle)

Enter the orientation of the tube side flowrate.

The ‘Angle of Outside Flow’ is assumed to approach the face of the tube
bundles in the perpendicular direction. Consequently, the plane in which the
tube bundle lies is determined by the angle of the outside flow.
If "Horizontal" (Default) is entered, the tubes are always horizontal regardless
of the Angle of Outside Flow.
If the Angle of Outside Flow is 90°, i.e. horizontal, and the Tube Side Flow
Direction is "Upward" then the tubes will be vertical with the fluid in the first
tube side pass flowing upwards. If the Tube Side flow direction is "Downwards"
then the tubes will be vertical with the fluid in the first tube side pass flowing
downwards.
If the Angle of Outside Flow is 0° or 180° (Up or Down), the Tube Side Flow
Direction has no effect, i.e. the tubes are always horizontal.

Other combinations of angles will produce bundle orientations partway

between the above extremes.

Tubes with inclination angles less then 5 degrees are considered horizontal.
 AirCooled: Fan Inlet Type
Program (conical)
None
Conical
Shallow radius
Deep radius
Shallow ellipse
Deep ellipse
Coefficient calculated
 AirCooled: Plenum Depth
Enter the Plenum Depth.
This is the distance from the bundle side of the fan ring to the bundle.
The default is 0.4 times the exchanger fan diameter.
 AirCooled: Ground clearance
Enter the distance from the ground to the fan inlet for a forced draught
exchanger or to the bundle entry for an induced draught exchanger.

Defaults to1.5 times the exchanger fan diameter.

 AirCooled: Chimney height above bundle
Enter the hardware height above the bundle, i.e. the distance from the top of
the bundle to the exchanger exit.
Only for use with the Natural Convection simulation option.
The hardware height acts as a 'chimney' filled with hot air.
For forced draught exchangers this will typically be the height of a wind skirt
above the bundle.
For induced draught exchangers it will be the distance to the top of the fan
casing.
Default value = 0.0
 AirCooled Bay Width
Specify the total width of the bay when you are modeling just one of multiple
services in a fan bay.
See also:
Multiple Services in Bay
 AirCooled: Louver type
Default (no louver)
Type A – DR54 p55
Type B – DR54 p55
Type C – DR54 p55
Type D – DR54 p55
Type k – loss coefficient input
 AirCooled: Louver opening angle
Enter either the louver opening angle (for louver types A-D) or the loss
coefficient (for louver type K).
An angle of 0° is fully open and 90° is fully closed.
 AirCooled: Louver pressure loss coefficient
Enter the pressure loss coefficient K for the louvers defined by
K = (Louvre Pressure Loss)/[0.5*(Air Density)*(Air Velocity above Bundle)2]
 AirCooled: Louver control
Program
None
Auto
Manual
Louvers are used to provide process side temperature control and prevent
damage to the bundle due to climatic conditions. Louvers affect the outside
bundle pressure drop and the price estimate.
 AirCooled: Steam coil
Program
Yes
No

This item is used only in the calculation of the X-side pressure drop. Steam
coils are assumed to consist of one row of tubes with the same tube geometry
as the first type of fin but with twice the transverse pitch
Steam coils are sometimes used to prevent freeze-up in the tubes during
severe climatic conditions.
 AirCooled: Width of sideframe including fin
clearance
Width of a single sideframe including fin clearance
Minimum Permitted 10 mm (0.4 Inch)
Maximum Permitted 2000 mm (78.7 Inches)
 AirCooled: Top of sideframe to edge of last tube
row fin
Minimum Permitted 0
Maximum Permitted 2000 mm (78.7 Inches)
 AirCooled: Bottom of sideframe to edge of 1st
tube row fin
Minimum Permitted 0
Maximum Permitted 2000 mm (78.7 Inches)
 AirCooled: Distance between bundles within
bays
The clearance between the sideframes of consecutive bundles within a bay.
For an induced draught exchanger with two tube bundles/bay then the
clearance can be typically 150 - 200 mm to enable the fan drive shafts from
the drive motors located below the bundles to be connected to the fans
located above the bundles.
Minimum Permitted 0
Maximum Permitted 1000 mm (39.4 Inches)
 AirCooled: Distance between bundles in
adjacent bays
This is the distance between the last sideframe of the last tube bundle in one
bay to the first sideframe of the first tube bundle in the next bay. Where bays
share support legs the value is likely to be less than when each bay has its
own supports.
Minimum Permitted 0
Maximum Permitted 3000 mm (118.1 Inches)
 AirCooled: Angle of sideframe to horizontal
The angle the tube bundle side frames to the horizontal. If the tube side
stream flows downhill in the first pass the angle is negative.
Minimum Permitted -60°
Maximum Permitted 60°
 AirCooled: Bundle drainage angle
Enter the angle of the bundle from the horizontal.
 AirCooled: Number of tube types
1, 2, 3, 4
Select the number of tube types in the bundle.
Tube types are numbered from the bottom of the bundle, i.e. the first row
encountered by the X-side stream.
 AirCooled: Tube shape
Round
Oval
Flat

If Oval or Flat tubes are selected, the geometric data for the tube should be
entered for each tube type on the Non-circular Tubes page. The geometric
data for each fin type can be entered on the Extended Surface input form.
 AirCooled: Tube (Material Type)
Select from the drop down list the required tube material type.
If you specify a material designator for the tube material, the program
retrieves the thermal conductivity of the tube from its built-in databank.
However, if you have a tube material that is not in the databank, you can
specify the thermal conductivity of the tube material on the Tube Properties
tab.
 AirCooled: Tube OD
Enter the outside diameter of the tube. Up to 4 Tube Diameters may be
specified.
Air-cooled Heat Exchangers
Normally these use tubes of carbon steel with attached fins. The requirement
for other tube materials depends on the operating temperature, pressure and
the corrosion characteristics of the process fluid. Tension wound fins of
aluminum are most commonly applied as: G-fin , L-fin or variations of these
types. Integral/bimetallic tubes are sometimes specified where an impervious
cladding of aluminum is perceived to minimise the potential for external
corrosion.
API661 recommends 25.4 mm or 1 inch as the minimum outside diameter. It
recommends the following minimum wall thickness for tubes in the range
25.4mm to 38.1mm, (1 inch to 1.5 inch) outside diameter:
· Carbon steel (maximum 9% chrome) 2.11 mm (0.083 inch)
· High alloy steel (austenitic or ferritic) 1.65 mm (0.065 inch)
· Nonferrous 1.65 mm (0.065 inch)
· Titanium 1.24 mm (0.049 inch)
For embedded fins the wall thickness is measured from the bottom of the
groove.
For vacuum condensation applications, diameters larger than 38.1mm (1.5
inch) may well be economic.
For small units where compliance with API661 is not required, tubes down to
12mm (0.5 inch) may be used. Often these will be constructed as tube-in-
plate bundles or use some form of proprietary fin. Tension wound fins can be
applied to tubes down to 2mm (0.08 inch).
Process Fired Heater Convection Banks
These usually use tubes with welded helical fins, both plain and serrated. The
former are sometimes known as solid fins and are best represented as
integral fins as a very high weld integrity between fin and base tube is usually
achieved. Tubes and fins will most commonly be carbon steel with alloy steels
being used in higher temperature applications. Serrated fins are represented
by general correlations. These can be specified with the same simple
dimensions of other helical fin types. Other applied fins are sometimes used in
these applications, the most common being stud types, usually with a circular
stud cross section.
API 560 recommends the following tube outside diameters: 2.375", 2.875",
3.50", 4.00", 4.50", 5.563", 6.625", 8.625", 10.75"
 AirCooled: Tube ID
Enter the inside diameter of the tube. Up to 4 Tube Diameters may be
specified.
Default values for Tube ID(1):
· Tube ID(1) = Tube OD(1) – 3.3mm(0.13in) for Air-cooled Heat
Exchangers
· Tube ID(1) = Tube OD(1) – 7.8mm(0.31in) for Other Crossflow Types
· Other tube types default to Tube ID(1).
 AirCooled: Fin material
Select a generic material for the Fins.
If you specify a material designator for the tube material, the program
retrieves the thermal conductivity of the tube from its built-in databank.
However, if you have a tube material that is not in the databank, you can
specify the thermal conductivity of the tube material on the Tube Properties
tab.
 AirCooled: Fin root diameter
Enter the root diameter for Integral, L-finned, Extruded tubes or Shoulder-
grooved fins. For other fin types, the fin root diameter is the base tube
outside diameter.
The Common Fin Root Diameter applies to the whole bundle unless a local
value is used.
Defaults to the tube outside diameter.
 AirCooled: Fin root thickness
Enter the root diameter for Integral Fin, L-fin, Extruded Fin or Shoulder-
grooved Fin.
For other fin types, the fin root diameter is the base tube outside diameter.
The Common Fin Root Diameter applies to the whole bundle unless a local
value for a Fin Type is set.
Defaults to the tube outside diameter.
 AirCooled: Major axis OD
For non-circular tubes enter the outside diameter of the major or larger axis.
 AirCooled: Minor axis OD
For non-circular tubes enter the outside diameter of the minor or small axis.
 AirCooled: Major axis fin OD
For non-circular tubes with fins enter the fin outside diameter of the major or
larger axis.
 AirCooled: Minor axis fin OD
For non-circular tubes with fins enter the fin outside diameter of the minor or
small axis.
 AirCooled: Heat transfer area scaler
This is a factor which scales up the heat transfer surface area of the finned
surface (based on the given fin parameters) to allow for enhanced surfaces
which are not currently handled by AirCooled.
e.g. rippled fin.
Note: A scaling factor can be applied to each tube type.
 AirCooled: Last row of tubes
Air coolers occasionally use more than one type of tube in different tube rows.
Tube types, like row numbers, are specified in order of air flow. You must
specify the last row in which a type occurs. The next type is assumed to begin
in the following row. It is not necessary to specify the last tube row for the
last tube type, since this must be the last row in the bundle.
 AirCooled: Serration width
Enter the width of the serration.
 AirCooled: Serration length
Enter the length of the serration.
 AirCooled: Serration fin method
PFR
Weierman
 AirCooled: Number of studs per crown
Enter the number of studs making up a crown.
 AirCooled: Stud width
Enter the stud width. This item is not required for circular studs.
 AirCooled: Effective tube length
Enter the length of tube that is exposed to heat transfer.
Inactive parts of a tube are where it fits into the tubesheets and comes into
contact with tube supports. Include these parts in the total Tube length.

There is no default value.

 AirCooled: Number of tube supports per bundle
Enter the number of tube supports along the length of each bundle.
 AirCooled: Tube support width
Enter the width of the tube support.
 AirCooled: Header type
Box
D-header
Plug
Cover Plate
Manifold
Box is a generic type, which covers Plug and Cover Plate.
 AirCooled: U-bend configuration
No U-bends (default)
U-bends in alternate passes
U-bends in every pass

Select the U-bend arrangement

 AirCooled: Depth of header
If known, enter the depth of the header(s).
For a D-header, this will be the maximum depth of the D-section.
Default = Minimum of 300mm (11.811 in) or 1.5 x Nozzle Inside Diameter
 AirCooled: Header wall thickness
Enter the wall thickness of the header.
 AirCooled: Tubesheet thickness
Enter the Tubesheet Thickness.
 AirCooled: Header side wall to tube edge
clearance
Enter the clearance between the side wall of the header and the closest tube.

Minimum Permitted 0
Maximum Permitted 300 mm (11.8 Inches)
 AirCooled: Header top wall to tube edge
clearance
Enter the clearance between the top wall of the header and the closest tube.

Minimum Permitted 0
Maximum Permitted 300 mm (11.8 Inches)
 AirCooled: Header bottom wall to tube edge
clearance
Enter the clearance between the bottom wall of the header and the closest
tube.

Minimum Permitted 0
Maximum Permitted 300 mm (11.8 Inches)
 AirCooled: Nominal pipe size
If using standard pipe for the nozzles, select the required Standard and
Nominal Pipe Size from the drop-down list. The program will look up the
corresponding Nominal Diameter and Actual OD and determine a Wall
Thickness and Actual ID based on an approximate mechanical calculation.
If not using standard pipe, then clear the NPS value by selecting the blank at
the top of the list and then specify an Actual OD or ID.
 AirCooled: Actual OD
Enter the outside diameter of the nozzles.
Defaults to the highest preferred diameter which gives a momentum flux
(rhoV2) less than 6000 kg/m s2.
Preferred sizes are; 50mm, 100mm, 150mm, 200mm etc.
 AirCooled: Actual ID
Enter the inside diameter of the nozzles.
Defaults to the highest preferred diameter which gives a momentum flux
(rhoV2) less than 6000 kg/m s2.
Preferred sizes are; 50mm, 100mm, 150mm, 200mm etc.
 AirCooled: Wall thickness
Enter the actual Wall Thickness of the Nozzle.
If not specified, the program will calculate this value.
 AirCooled: Quantity
Enter the number of nozzles per bundle.
It should be noted that too few nozzles can cause excessive pressure losses
and possibly erosion of the nozzles and headers.
Default value: 1
 AirCooled: Orientation
Enter the orientation of the nozzles.
 AirCooled: Length
Enter the length of the nozzle.
 AirCooled: Flange thickness
Enter the thickness of the nozzle flange.
 AirCooled: Flange diameter
Enter the diameter of the nozzle flange.
 AirCooled: Nozzle flange rating
The specification of the nozzle flange rating does not affect the thermal
design calculations or the cost estimate. It is included in the input to make
the specification of the heat exchanger more complete.
The pressure-temperature charts are built into the program. The program
determines the rating based on the design pressure, design temperature, and
material of construction.
The values are not limited to those shown next to the input field, but you
should be sure to choose a rating that is consistent with the desired standard
(ANSI, ISO, or DIN).
 AirCooled: Nozzle flange type
Select the nozzle flange type from the following list:
Slip-on
Lap Joint
Weld Neck
Long Weld Neck
Self-reinforced
 AirCooled: Fan Drive Type
Right Angle Gear
V-Belt
Direct
 AirCooled: Fan Pitch Control
None
Adjustable
Auto
 AirCooled: Fan Selection Method
Set default
Standard
Moore Fan

The Standard fans option will size and rate fans based on generic fan
correlations which do not apply to any commercial fan manufacturer.
The Moore fans option will size and rate fans based on manufacturer supplied
correlations and should reflect the actual performance of the manufacturer’s
fans.
 AirCooled: Fan Speed (rpm)
Fan shaft rotational speed. (i.e rpm = revolutions per minute)
 AirCooled: Fan Drive Efficiency %
The efficiency of the drive in converting the motor horsepower to total air
horsepower output. Fan drive efficiency = Total Air HP output/Brake HP Input.
Generally in the range of 60-90%.
 AirCooled: Fan Static Efficiency %
The fan static efficiency is used in selecting the proper blower for an given
installation. The static efficiency neglects the velocity pressure imparted to
the air, and considers only the volumetric flow delivered against the static
pressure. Static efficiency = Static air HP output/Brake HP Input.
 AirCooled: Use Input Fan Curve
Check the box to specify enable the Fan Curve tab
 AirCooled: Characteristic Fan Diameter
The fan blade diameter used for the associated fan performance curve.
 AirCooled: Characteristic Fan Speed (rpm)
The blade tip speed used for the associated fan performance curve.
 AirCooled: Reference Air Density
The air density used for the associated fan performance curve.
 AirCooled: Volumetric Flow Rate
Enter the fan Volumetric Flow Rate for a specific point on the fan
characteristic curve.
You can enter four to eight sets of values comprising volumetric flowrate, fan
static pressure, and fan static efficiency which fully describe the fan
characteristic curve. The values must be entered in ascending order of
volumetric flowrate.
 AirCooled: Static Pressure
Enter the fan static pressure for a specific point on the fan characteristic
curve.
You can enter four to eight sets of values comprising volumetric flowrate, fan
static pressure, and fan static efficiency which fully describe the fan
characteristic curve. The values must be entered in ascending order of
volumetric flowrate.
 AirCooled: Static Efficiency
Enter the fan Static Efficiency for a specific point on the fan characteristic
curve.
You can enter four to eight sets of values comprising volumetric flowrate, fan
static pressure and fan static efficiency which fully describe the fan
characteristic curve. The values must be entered in ascending order of
volumetric flowrate.
The fan static efficiency is used in selecting the proper blower for a given
installation. The static efficiency neglects the velocity pressure imparted to
the air and considers only the volumetric flow delivered against the static
pressure.
Static Efficiency = Static Air HP output / Brake HP Input
 AirCooled: Plenum Type
Box type plena can be specified for both forced and induced draught
exchangers with sloping or horizontal tube bundles. Transition plena can be
specified for the bundles of forced and induced draught exchangers with
horizontal side-frames.
 AirCooled: Transition Plenum Wall Length
In Rating/Checking or Simulation mode enter a value if known.
 AirCooled: Transition Plenum Wall Length to
Fan Diameter Ratio
Transition plena are assumed to converge from the tube bundles to squares
located around each fan ring. This ratio determines the size of the square
relative to the fan diameter.

Minimum Permitted 1
Maximum Permitted 2
 AirCooled: Plenum Depth to Fan Diameter Ratio
This is the depth of each plenum chamber below or above each bundle
sideframe relative to the fan diameter.

Minimum Permitted 0.05

Maximum Permitted 5
 AirCooled: Fan Ring Length in Airflow Direction
In Rating/Checking or Simulation mode enter a value if known.
 AirCooled: Fan Ring Length in Airflow Direction
to Fan Diameter Ratio
This ratio determines the length of the fan ring. This length is independent of
the fan entry length, which is determined by the type of fan entry.

Minimum Permitted 0.05

Maximum Permitted 2
 AirCooled: Position of Fan Ring in Plenum
In Rating/Checking or Simulation mode enter a value if known.
 AirCooled: Position of Fan Ring in Plenum to
Fan Ring Length Ratio
This ratio determines where along the length of a fan ring the ring is attached
to a plenum floor. If the ratio is zero the fan entry is attached directly to the
plenum floor whereas if it is 1 then the full length of the fan ring is outside
the plenum.

Minimum Permitted 0
Maximum Permitted 1
 AirCooled: Plenum Chamber Side to Bundle
Frame X Clearance
This is the clearance in the X direction between the sidewalls of the plenum
chamber(s) and the outer edges of the bundle sideframes at each side of a
bay. A positive clearance places the plenum chamber sidewalls inside the
sideframes and a negative clearance places the sidewalls beyond the bundle
sideframes.

Minimum Permitted -5000 mm (-196.9 Inches)

Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Plenum Chamber Side to Tubesheet
Z Clearance
This is the clearance in the Z direction between the end walls of the plenum
chamber(s) and the tube side of the bundle tube sheets at each end of a bay.
A positive clearance places the plenum chamber end walls inside the tube
sheets and a negative clearance places the end walls beyond the bundle tube
sheets.

Minimum Permitted -5000 mm (-196.9 Inches)

Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Fan Entry Lip Width in the Radial
Direction
It is assumed that a strengthening ring is welded to the fan entry lip and this
dimension is the radial width of the ring.

Minimum Permitted 0
Maximum Permitted 500 mm (19.7 Inches)
 AirCooled: Fan Center Offset from Plenum
Center
The centerlines of each fan are assumed to be midway within the plena when
viewed from the front. A positive offset will move all of the fans to the right
and vice versa.

Minimum Permitted -5000 mm (-196.9 Inches)

Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Fan Motor Orientation
Up
Horizontal
Down
The axis of each fan motor can be vertical with the motor drive shaft pointing
downwards or upwards or alternatively the axis can be horizontal. When
horizontal, the fan drive shaft always points towards the fan centerline.
 AirCooled: Vertical Distance from Fan Motor
Shaft End to Fan Center
This dimension determines the vertical location of the fan motors. The fan is
assumed to be centrally located along the length of the fan ring, not including
the fan entry. The dimension is the vertical component of the distance
between the fan centre and the centre of the end of the motor drive shaft.

Minimum Permitted 0
Maximum Permitted 1000 mm (393.7 Inches)
 AirCooled: Radial Distance from Fan Motor
Shaft End to Fan Center
This dimension together with the angle in the XZ plane determines the
horizontal position of the fan motors. This dimension is the horizontal radial
distance of the centre of the end of the motor drive shaft from the fan
centerline of the fan served by the motor. If this dimension is set to zero and
the motor is orientated vertically upwards then a direct drive can be
represented.

Minimum Permitted 0
Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Fan Motor Body Length
This is the length the body of a fan drive motor along the motor centerline. It
does not include the length of the motor shaft.
 AirCooled: Fan Motor Body Diameter
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This diameter is the diameter of the central section of
the motor and is used for proportioning the diameters of the other motor
sections.
 AirCooled: Fan Motor Shaft Length
This is the length of the motor shaft protruding from the body of the motor.
The end of the motor shaft furthest from the body of the motor is the datum
for locating the motor in relation to the fan it serves.
 AirCooled: Fan Motor Shaft Diameter
This is the diameter of the motor shaft protruding from the body of the motor.
 AirCooled: Length of Motor Section Nearest
Shaft/Motor Length
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This ratio determines the length of the part of the
motor adjacent to the drive shaft.
 AirCooled: Length of Motor Section Nearest
Shaft
This input, available in Rating/Checking and Simulation mode, allows the
actual dimension to be specified which will override the Length of motor
section nearest shaft / motor length ratio.
This value is not used in the calculations, but is used in the Setting Plan
drawing.
 AirCooled: Diameter of Motor Section Nearest
Shaft/Motor Diameter
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This ratio determines the diameter of the part of the
motor adjacent to the drive shaft.
 AirCooled: Diameter of Motor Section Nearest
Shaft
This input, available in Rating/Checking and Simulation mode, allows the
actual dimension to be specified which will override the Diameter of motor
section nearest shaft / motor diameter ratio.
This value is not used in the calculations, but is used in the Setting Plan
drawing.
 AirCooled: Corner Radius of Near Motor
Section/Motor Length
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This ratio determines the radius on the corner of the
part of the motor adjacent to the drive shaft when viewing the motor from the
side. If a value greater than half the 'length of motor section nearest shaft /
motor length' is entered the value is changed to half this length ratio.
 AirCooled: Corner Radius of Nearest Motor
This input, available in Rating/Checking and Simulation mode, allows the
actual dimension to be specified which will override the Corner Radius of near
motor section / motor length ratio.
This value is not used in the calculations, but is used in the Setting Plan
drawing.
 AirCooled: Length of Far Motor Section/Motor
Length
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This ratio determines the length of the part of the
motor furthest from the drive shaft.
 AirCooled: Length of Motor Section Farthest
from Shaft
This input, available in Rating/Checking and Simulation mode, allows the
actual dimension to be specified which will override the Length of far motor
section / motor length ratio.
This value is not used in the calculations, but is used in the Setting Plan
drawing.
 AirCooled: Diameter of Far Motor Section/Motor
Diameter
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This ratio determines the diameter of the part of the
motor furthest from the drive shaft.
 AirCooled: Diameter of Motor Section Farthest
from Shaft
This input, available in Rating/Checking and Simulation mode, allows the
actual dimension to be specified which will override the Diameter of far motor
section / motor diameter ratio.
This value is not used in the calculations, but is used in the Setting Plan
drawing.
 AirCooled: Corner Radius of Far Motor
Section/Motor Length
To provide realistic representations of fan drive motors it is assumed that the
body of the motor is divided into three sections which can be of different
diameters and lengths. This ratio determines the radius on the corner of the
part of the motor adjacent to the drive shaft when viewing the motor from the
side. If a value greater than half the 'length of motor section nearest shaft /
motor length' is entered the value is changed to half this length ratio.
 AirCooled: Corner Radius of Farthest Motor
This input, available in Rating/Checking and Simulation mode, allows the
actual dimension to be specified which will override the Corner Radius of far
motor section / motor length ratio.
This value is not used in the calculations, but is used in the Setting Plan
drawing.
 AirCooled: Angle in XZ Plane of All But Last Fan
Motor
The X axis is assumed to be the axis from left to right in a front elevation and
the Z axis is the axis from left to right in a side elevation of an exchanger
unit. The XZ plane is therefore the plane seen in a plan view of a unit. The
origin of angles in the XZ plane is assumed to be the X axis and positive
angles are measured in the anti-clockwise direction and vice versa. Fan
motors offset from the fan centerlines are assumed to be in the same position
for all fans except the last fan in a bay which can have a different angular
coordinate.

Minimum Permitted -180°

Maximum Permitted 180°
 AirCooled: Angle in XZ Plane of Last Fan Motor
The X axis is assumed to be the axis from left to right in a front elevation and
the Z axis is the axis from left to right in a side elevation of an exchanger
unit. The XZ plane is therefore the plane seen in a plan view of a unit. The
origin of angles in the XZ plane is assumed to be the X axis and positive
angles are measured in the anti-clockwise direction and vice versa. Fan
motors offset from the fan centerlines are assumed to be in the same position
for all fans except the last fan in a bay which can have a different angular
coordinate.

Minimum Permitted -180°

Maximum Permitted 180°
 AirCooled: Bays share support legs
Each bay can either have its own legs to support it independently of other
bays or adjacent bays can share legs positioned midway between the bays.
 AirCooled: Number of support legs in Z
direction
Any number of support legs greater or equal to 2 can be specified along each
side of a bay in the direction of the tube bundles. The positions of the legs
nearest the bay corners are determined by the leg clearances and any
intermediate legs are equally spaced between the corner legs.

Minimum Permitted 2
Maximum Permitted 15
 AirCooled: Corner support leg width in the X
direction
This is the width of every support leg when viewed from the front of the
exchanger.

Minimum Permitted 10 mm (0.4 Inch)

Maximum Permitted 2000 mm (78.7 Inches)
 AirCooled: Corner support leg depth in the Z
direction
This is the depth (or width) of every support leg when viewed from the side of
the exchanger in the direction of the tube bundles.

Minimum Permitted 10 mm (0.4 Inches)

Maximum Permitted 2000 mm (78.7 Inches)
 AirCooled: Ratio of fan entry height above
ground to fan diameter
This is the ratio of the distance of the fan entry inlet lip above the ground or
pipe rack to the fan diameter. This ratio is the main component in the
calculation of the height of the exchanger above the ground.

Minimum Permitted 0.1

Maximum Permitted 10
 AirCooled: Tubesheet or plenum end to support
leg clearance
For forced draught exchangers with box plena the legs are assumed to be
attached to the bottoms of the plena and for other exchanger configurations
the legs are assumed to be attached directly to the bundle sideframes. This
clearance is the distance the outer edges of the legs are from the ends of the
plena or tubesheets in the Z direction that is along the length of the tube
bundles. Positive clearances move the legs towards the centre of a bay and
vice versa.

Minimum Permitted -2000mm (-78.7 Inches)

Maximum Permitted 2000 mm (78.7 Inches)
 AirCooled: Sideframe or plenum side to support
leg clearance
For forced draught exchangers with box plena the legs are assumed to be
attached to the bottoms of the plena and for other exchanger configurations
the legs are assumed to be attached directly to the bundle sideframes. This
clearance is the distance the outer edges of the legs are from the sides of the
plena or tubesheets in the X direction that is sideways when viewing the
exchanger from the front. Positive clearances move the legs towards the
centre of a bay and vice versa.

Minimum Permitted -2000 mm (-78.7 Inches)

Maximum Permitted 3000 mm (118.1 Inches)
 AirCooled: Header Walkway
Select whether a walkway is required at the header level.
 AirCooled: Header walkway width
The width of the header walkways. The walkway railings are assumed to have
negligible width.

Minimum Permitted 300 mm (11.8 Inches)

Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Header walkway floor to bottom of
header distance
This dimension locates the vertical positions of the header walkways and is
the distance of the top of the walkway floor from the outer bottom edge of the
header the walkway is serving.

Minimum Permitted 0
Maximum Permitted 2500 mm (98.4 Inches)
 AirCooled: Header walkway offset from the
headers
This dimension locates the horizontal positions of the header walkways and is
the horizontal gap between the walkway floor and the outer bottom edge of
the header the walkway is serving.

Minimum Permitted 0
Maximum Permitted 1500 mm (59.1 Inches)
 AirCooled: Bay Walkway
Select whether a walkway is required between the bays.
 AirCooled: Bay walkway width
The width of the walkway that serves every bay. The walkway railings are
assumed to have negligible width.

Minimum Permitted 300 mm (11.8 Inches)

Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Bay walkway offset from expected
position
For units with one fan per bay the expected position of the between bay
walkway is evenly situated below the fan centerlines. For units with more
than one fan per bay the expected position of the between bay walkway is
midway between the centerlines of the first and second fans. A positive offset
can be applied which will move the walkway towards the other header or a
negative offset will move it towards the inlet header.

Minimum Permitted -10000 mm (-393.7 Inches)

Maximum Permitted 15000 mm (590.6 Inches)
 AirCooled: Fan Walkway
Select whether a walkway is required under the fans.
 AirCooled: Fan walkway width
The width of the walkway for accessing the individual fans in each bay. The
width of this walkway may be greater than the other walkways to provide
ready access to the fan motors.

Minimum Permitted 300 mm (11.8 Inches)

Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Fan walkway offset from fan
centerlines
The fan walkways are expected to be evenly situated about the fan
centerlines. A positive offset can be applied to move the walkway to the right
or vice versa when viewed from the front.

Minimum Permitted -7000 mm (-275.6 Inches)

Maximum Permitted 7000 mm (275.6 Inches)
 AirCooled: Fan walkway length beyond centers
of end fans
This is the distance the fan walkways extend beyond the end fan centerlines
towards the headers.

Minimum Permitted 0
Maximum Permitted 5000 mm (196.9 Inches)
 AirCooled: Walkway floor thickness
Enter the overall thickness or depth of every walkway floor.

Minimum Permitted 5 mm (0.2 Inches)

Maximum Permitted 500 mm (19.7 Inches)
 AirCooled: Walkway railing height
This is the height of the railings for every walkway. On the setting plan the
railings on the header walkways adjacent to the headers are drawn at half the
railing height.

Minimum Permitted 100 mm (3.9 Inches)

Maximum Permitted 2500 mm (98.4 Inches)
 AirCooled: Walkway railing post spacing
Equal railing post spacing is chosen for each walkway such that the post
spacing is equal to or less than the maximum spacing.

Minimum Permitted 100 mm (3.9 Inches)

Maximum Permitted 3000 mm (118.1 Inches)
 AirCooled: Walkway distance below ring fans
This dimension determines the vertical position of the fan and bay walkways
and it usually chosen to be suitable for a person to walk unimpeded under the
fan rings for a forced draught unit or under the bundles for an induced
draught unit.

Minimum Permitted 500 mm (19.7 Inches)

Maximum Permitted 4000 mm (157.5 Inches)
 AirCooled: Header (Material Type)
Select from the drop down list the required header material type.
If you specify a material designator for the tube material, the program
retrieves the required material properties from its built-in databank.
However, if you have a header material that is not in the databank, you can
specify the density of the header material.
 AirCooled: Tubesheet (Material Type)
Select from the drop down list the required tube material type.
If you specify a material designator for the tubesheet material, the program
retrieves the required material properties from its built-in databank.
 AirCooled: Fin Thermal Conductivity
If you have selected a Fin Material, the program retrieves the thermal
conductivity of the fins from its built-in databank. However, if you have a fin
material that is not in the databank, you can specify the thermal conductivity
of the fin material.
 AirCooled: Fin Material Density
If you have selected a Fin Material, the program retrieves the density of the
fins from its built-in databank. However, if you have a fin material that is not
in the databank, you can specify the density of the fin material.
 AirCooled: Tube Thermal Conductivity
If you have selected a Tube Material, the program retrieves the thermal
conductivity of the tubes from its built-in databank. However, if you have a
tube material that is not in the databank, you can specify the thermal
conductivity of the tube material.
 AirCooled: Tube Material Density
If you have selected a Tube Material, the program retrieves the density of the
tubes from its built-in databank. However, if you have a tube material that is
not in the databank, you can specify the density of the tube material.
 AirCooled: Header Density
If you have selected a Header Material, the program retrieves the density of
the header from its built-in databank. However, if you have a header material
that is not in the databank, you can specify the density of the header
material.
 AirCooled: Tube Length Increment
When in Design mode, enter the tube length increment which you would like
the program to use when it is changing the tube length to optimize the
geometry.
See Also:
AirCooled Tube Length Minimum / Maximum
 AirCooled: Tube Length Minimum / Maximum
When in Design mode, enter the Minimum / Maximum tube length that the
program should consider. The tube length includes the ends fitted into the
tubesheets and where the tube comes into contact with tube supports.
See Also:
AirCooled Tube Length Increment
 AirCooled: Bay Width Minimum / Maximum
When in Design mode, enter the Minimum / Maximum bay width that the
program should consider.
Bays consist of a duct like framework in which one or more bundles are
positioned side by side with the tube bundle length extending along the
length of the bay. Multiple fans can be positioned above or below the bay
along the length of the bay to force air flow across the bundles. There is
generally only one fan across the width of the bay. Multiple bays can be
positioned parallel to one another to comprise an entire unit. The maximum
and minimum bay width selection is generally determined based on
availability of space and the diameter of the fans to be used.
 AirCooled: Bundle Width Minimum / Maximum
The Minimum Bundle Width is usually determined by economic factors.
Each Bundle must have at least two connections to external pipework (for
supply and return of process fluid). A small bundle width will result in a large
number of bundles being required for a given duty and hence a high cost for
pipework connections. In addition, each bundle requires the structural support
of side frames. These consume plot space or frontal area without contributing
to heat transfer. Thus more bundles for a given process duty will result in a
more expensive unit consuming a greater plot area. Side-frames and nozzles
& connections also contribute to a weight overhead.
The Maximum Bundle Width is usually limited by how the bundle will be
transported from the factory to the site. A bundle width of 3m (9.7ft) is a
practical unit for conventional road transport.
 AirCooled: Tube support spacing
Enter the center to center spacing of tube supports. Tube supports are
provided to provide stability to the bundle and prevent undo sagging of long
unsupported tube lengths.
 AirCooled: Tube passes per bundle
Enter the maximum number of tube side passes to be considered in the
Design search.
With four or more passes the exchanger tends towards the ideal of a pure
counter current or co-current exchanger.
 AirCooled: Bays per Unit Minimum / Maximum
When in Design mode, enter the Minimum / Maximum Number of Bays per
Unit.
 AirCooled: Tube pass options
In Design mode, this item provides options to specify that only odd or even
numbers of tube passes are considered in the design search. The default is all
numbers of passes between 1 and the maximum number of tube passes per
bundle.
 AirCooled: Tube side fluid velocity
For Design mode only, enter the maximum allowable velocity in the tubes.
Any feasible design will have a tube side velocity less than or equal to this
value.
You must specify either the Maximum Tube side Rho V2 or the Maximum Tube
side Velocity allowed.
Low velocities are to be avoided as they promote fouling.
High velocities are to be avoided as they may result in erosion of tube entry
or exit regions.
A default value for Maximum Tube side Rho V2 is used instead of this item.
 AirCooled: Outside fluid face velocity
This input refers to the velocity just upstream of the tube bundle and is
usually known as the air face velocity. The AirCooled design logic attempts to
find a design that gives an air face velocity between the input minimum and
maximum values, subject to the allowable airside pressure drop. You can use
this input to constrain the air face velocity in Design mode within specific
limits.
 AirCooled: Tube side RhoV2
For Design mode only, enter the maximum allowable value of Rho V2
(product of density and the square of the mean velocity) in the tubes. Any
feasible design will have a Rho V2 value less than or equal to this value.
Note: You should specify either the Maximum Tube side Rho V2 or the
Maximum Tube side Velocity allowed. To avoid erosion in the tubes the value
of Rho V2 should be set equal to 6000 kg/ms2 (~4000 Ib/fts2). Higher values
are to be avoided as these may cause erosion of tube material.
Default value = 6000 kg/ms2 (4032 Ib/fts2)
 AirCooled: Fan power maximum
Design constraint which controls the design optimization of the program to
arrive at a design which consumes less power than what was specified. If this
limit is approached, the program will attempt to reduce the X-side pressure
drop by widening the bay and reducing the X-flow velocity. This will result in
lower X-flow heat transfer and possibly more heat transfer area
 AirCooled: Maximum tube side nozzle pressure
loss%
For Design mode only, enter the maximum allowable tube side pressure drop
through the tubes.
This value is used to produce an outline design and should exclude nozzle and
header pressure losses. For more accurate determination of total tube side
pressure drop you should run a simulation from the selected design.
For vacuum units or units where the expected pressure drop is a substantial
fraction of the absolute pressure at inlet it is recommended that you run the
simulation with the pressure dependence option selected.
Default value = 0.2 bar (2.9 psi, 0.204 kgf/cm2)
 AirCooled: Temperature approach limit
The temperature approach limit is the limit at which the program will allow
the hot side outlet temperature to approach the cold side inlet temperature or
will allow the cold side outlet temperature to approach the hot side inlet
temperature. This limit is used in the programs simulation mode of outlet
temperatures.
 AirCooled: Outlet temperature of x-flow stream
The minimum and maximum outlet temperature of the outlet stream
represent the outer limits of acceptable temperatures to be used in evaluating
different X-flow stream flows. These temperatures as well as a number of
temperature points between them will be selected for evaluation. Given the
specified inlet temperature and one of these outlet temperatures and the heat
load requirement defined by the opposite side, the program will calculate a
required X-side flow rate. The resulting process conditions will then be used to
optimize the geometry of the exchanger.
 AirCooled: Number of outlet temperatures to
evaluate
The number of outlet temperatures between and including the specified
minimum and maximum which will be used in the evaluation of different flow
and geometry combinations. A new geometry will be optimized for minimum
heat transfer area for each flow condition.
 AirCooled: Optimization criteria
There are four optimization criteria available. Minimum capital cost, minimum
capital and operating cost, minimum area, and maximum face velocity. After
all outlet temperature points and corresponding flows have been evaluated,
the program selects the best candidate that meets the defined criteria and
shows it as the final design.
 AirCooled: Period of operation to estimate
power cost
The operating cost is based on this specified period of operation.
 AirCooled: Power cost per kW-Hr
The operating cost is based on this specified power cost.
 AirCooled: Maximum number of design mode
iterations
This is an advanced control option, which can normally be defaulted.
This is the maximum number of iterations AirCooled will use when attempting
to find a valid exchanger heat duty. The default is 60 iterations. This may not
be sufficient for exchangers with many tube rows. AirCooled outputs a
warning message if this limit is reached and the program execution stops.
For counter-current exchangers try re-running the program with the Tube
side Inlet Temperature Simulation Option before using this item.
Default: 500
 AirCooled: Vapor heat transfer coefficient
A value entered here will override the gas (or vapor) heat transfer coefficient
calculated by AirCooled. A value for the tube side should be referred to the
tube inside diameter. A value for the X-side should be referred to the tube
diameter.
Note 1: Users will normally find that the coefficients calculated by the
program represent the best available predictions. Where there are special
circumstances where the internally calculated values are not appropriate then
this item should be used to override the calculated values.
Note 2: Coefficients may be entered for the single phase liquid, two phase or
single phase vapor regions as required. If a constant coefficient is required in
all three regions, then the same value must be entered for each item.
 AirCooled: 2-phase heat transfer coefficient
A value entered here will override the tube side two phase liquid heat transfer
coefficient calculated by AirCooled. This value should be referred to the tube
inside diameter.
Note 1: Users will normally find that the coefficients calculated by the
program represent the best available predictions. Where there are special
circumstances where the internally calculated values are not appropriate then
this item should be used to override the calculated values.
Note 2: Coefficients may be entered for the single phase liquid, two phase or
single phase vapor regions as required. If a constant coefficient is required in
all three regions, then the same value must be entered for each item.
 AirCooled: Liquid heat transfer coefficient
A value entered here will override the tube side single phase liquid heat
transfer coefficient calculated by AirCooled. This value should be referred to
the tube inside diameter.
Note 1: Users will normally find that the coefficients calculated by the
program represent the best available prediz`ctions. If there are special
circumstances where the internally calculated values are not appropriate then
this item should be used to override the calculated values.
Note 2: Coefficients may be entered for the single phase liquid, two phase or
single phase vapor regions as required. If a constant coefficient is required in
all three regions, then the same value must be entered for each item.
 AirCooled: Calculation steps per tube
Enter the number of calculation steps per tube in the range 3 to 20.
A small number will significantly reduce the time taken by AirCooled to reach
a solution especially for exchangers with complex pass arrangements.
However, the accuracy of the answers may be suspect.
It is recommended that when looking for an approximate design a small
number is used and then the default number of 12 or greater is used for the
final design.
 AirCooled: Number main iterations
This is an advanced control option, which can normally be defaulted.
This is the maximum number of iterations AirCooled will use when attempting
to find a valid exchanger heat duty. The default is 60 iterations. This may not
be sufficient for exchangers with many tube rows. AirCooled outputs a
warning message if this limit is reached and the program execution stops.
For counter-current exchangers try re-running the program with the Tube
side Inlet Temperature Simulation Option before using this item.
Default: 60
 AirCooled: Detailed calculation accuracy %
This is an advanced control option, which can normally be defaulted.
Convergence at each tube step of a representative tube is deemed to have
occurred if the difference between the tube side enthalpy change calculated
by the program over the step and the enthalpy change at the previous
iteration is within 4%. If convergence has not been obtained it may be
necessary to decrease this value to get results that are more accurate.
Decreasing the value of this tolerance will increase the computational time.
Please try using the Tube side Inlet Temperature Simulation Option or
increase the number of main iterations first.
Default: 4
 AirCooled: Main iteration accuracy %
This is an advanced control option, which can normally be defaulted.
AirCooled is deemed to have converged if the difference between the overall
tube side enthalpy change calculated by the program and the enthalpy change
at the previous iteration is within 0.2%. If you require convergence to 0.1%
of the enthalpy change you would enter a value of 0.1.
This value should only change when there are serious convergence problems.
If a solution has not been obtained try using the Tube side Inlet Temperature
Simulation Option or increase the number of main iterations.
 AirCooled: Use wet wall desuperheating for
condensation applications
Check the box to use wet wall desuperheating for condensing applications.
Note:
Wet wall desuperheating occurs when the bulk temperature of a stream is
above the dew point, but the local wall temperature is below the dew point. If
the wet wall calculation is selected, the program corrects the heat transfer
rate in the desuperheating zone to allow for condensation occurring at the
wall.
When the alternative dry wall calculation is selected the program uses the
single phase gas coefficient until the bulk vapor temperature reaches the dew
point. As a rule, dry wall coefficients are usually lower than wet wall
coefficients, and hence more conservative.
 AirCooled: Tube side flow distribution
Select one of the following to describe how AirCooled should handle the tube
side flow:
· Activated
· Not Activated
· Phase Separation

Activated
This option will adjust the tube side flowrate within each pass to equalize the
tube side pressure drop through every representative tube in each pass.
This is valuable when modeling condensers where tube layers with a higher
temperature difference can condense more vapor. The associated pressure
recovery results in higher flowrates entering the layers. It is useful to gauge
the effect on the overall duty but it should be borne in mind that practical
processes such as phase separation are neglected in such analyses (see
Distributed Flow with Phase Separation).
Restrictions:
1. This option should not be used for condensers with a significant tube slope,
> 5 degrees.
2. This option cannot be used in exchangers where passes are connected with
U tubes.
Not Activated
By default the program assumes equal flowrates through every tube in a pass.
Phase Separation
This models two-phase flow entering a box header of a horizontal multi-row
condenser where the phases tend to separate such that the liquid flows
through the lower rows of the pass and the vapor through the upper rows.
The flowrates through the different tube rows adjust so that the pressure drop
over each row is the same.
Restrictions:
1. This option should not be used for condensers with a significant tube slope,
> 5 degrees.
2. This option cannot be used in exchangers where passes are connected with
U tubes.
Note: The method is based on maximum separation in steam condensers. For
full details of the method please see: HTFS Research Report RS1057 (1999)
by P E Farrant.
 AirCooled: Velocity heads for perforated pass
plate pressure drop
The number of velocity heads to be used for calculating the pressure drop
across the perforated pass partition plates.
 AirCooled: Viscosity Method for Two Liquid
Phases
You can select one of five methods for calculating the effective viscosity of
two liquid phases.
· The HTFS selected method (HTFS emulsion for single phase and boiling,
higher viscosity for condensing)
· The HTFS emulsion method
· The HYSYS emulsion method
· Use higher viscosity
· The old HTFS method (the only option in V7.3.1 and earlier)
Since predictions can have significant uncertainty even with the HTFS
selected method, you can use the other methods to understand how much
these uncertainties affect exchanger design.
Usually, a case with two liquid phases involves oil and water, so we will refer
to the higher viscosity liquid as oil, and the lower viscosity liquid as water.
The flow is often in the form of an emulsion, which means droplets of one
phase are carried along by the flow the dominant, continuous phase. The
presence of such droplets can significantly increase the viscosity of the
dominant phase, so effective viscosities higher than either the oil or water
often occur.
When one phase is present in relatively small amounts, the situation is
straightforward, but when the amounts of the phases are comparable,
significant uncertainties can appear. As the amount of oil increases, the
continuous phase eventually changes from water to oil. This change can lead
to a very large increase in effective viscosity.
An emulsion does not always occur. In condensation, the flow is often
filmwise, with one fluid on top of or in parallel with the other. In such cases,
using the higher viscosity is good practice.
The HTFS selected method uses the higher viscosity method for condensing
flows, and the new HTFS emulsion method for single phase and boiling flows.
The old HTFS method is the basic Brinkman method, an emulsion method in
which the effective viscosity of the dominant phase varies inversely as its
volume fraction to the power of 2.5. The lower of the two effective viscosities
is used. An ad hoc viscosity reduction is applied in the (unusual) event of the
effective viscosity being more than twice the higher individual phase viscosity.
The new HTFS recommended method has two improvements. The first is that
there is explicit prediction of the inversion point, which is normally in the
range 0.45 to 0.75 for volume fractions of oil. The higher the oil viscosity, the
higher the inversion point volume fraction. The power used to determine
effective phase viscosity is also lower: it will be relatively close to 2.5 for the
water dominant region but is lower for the oil, falling to near unity for very
high viscosity oil. The region of rapid viscosity change is assumed to occur
over an oil volume fraction range 0.1 below the inversion point.
The HYSYS method does not use a Brinkman type power law equation for
effective viscosity, but the resulting viscosities are broadly similar to using a
power of 2.5. The major difference is that the oil is assumed to be dominant
for oil volume fractions above 0.5, and the water is assumed to be dominant
below 0.33. A weighted mean is used in the transition region.
The option to use the higher viscosity uses the oil viscosity as long as the
volume fraction of oil is above 5%, below which there is a linear transition
down to the pure water value. This method might be more appropriate in
downflow condensation cases or falling film evaporators where there is film
flow rather than droplet flow. It can also be used to avoid uncertainties
associated with being one side or other of a step change near the inversion
point.
Of the three methods for emulsions, the HYSYS method will give the highest
viscosity for oil volume fractions above 0.33. The new HTFS method will give
slightly lower effective viscosities than the old method in the water dominant
region, and somewhat larger reductions in the oil dominant region. The oil
dominant region will however extend to lower oil volume fractions.
Differences between the predictions of the three methods will generally be
larger for heavy oils than for light oils.
A warning message is produced whenever the oil volume fraction is in or near
the transition region for a method. Another message is produced whenever a
predicted viscosity is more than 50% greater than the oil viscosity. Both
messages give the temperature range where these conditions occur. The
range may extend to temperatures beyond that of the bulk fluid, since
viscosities often need to be evaluated at wall temperatures as well as bulk
temperatures.
 AirCooled: Highfin Tube Calculation Method
The program provides a choice of method for calculating heat transfer and
pressure drop in crossflow over bundles of high-finned tubes.
The default method for typical air-cooler finned tube geometries is HTFS3-
AC. This is a special version of HTFS3a that has been optimized using data for
finned tube bundles that are typical of those used in air-coolers. It is
documented in HTFS RS1197 and is applied if the following conditions are
met:
· Air temperature between 20 degC and 80 degC
· Air face velocity between 1 and 9.5 m/s
· Tube outside diameter between 25 and 32 mm
· Fin frequency between 350 and 440 fins/m
· Fin thickness between .25 and .47 mm
· Fin tip gap between 2.5 and 11 mm
The method, HTFS3A, has been developed from an HTFS research program
spanning a number of years, and it addresses both heat recovery and air-
cooled heat exchanger tube geometries. It applies to bundles of plain helical
fins (Fin types: Integral; G; L; Bi-metallic; extruded; Shoulder-grooved) in
staggered and in-line arrangements. It is documented in Handbook Sheets
AM2 and AM4.
The PFR 1976 method is an open-literature correlation that was originally
applied in earlier versions of ACOL, but was superseded by the HTFS3A
method which has been shown to give improved accuracy. It can be applied to
all extended surface types and is recommended as the default method for
tube-in-plate exchangers and for studded tubes.
The ESCOA, or Weierman, method can be applied to plain and serrated fins
and it is the default method for serrated fins.
 AirCooled: Lowfin Tube Calculation Method
HTFS/ESDU, the default method for heat transfer and pressure drop in
crossflow over low-finned tubes, was adapted by HTFS from the correlations
published by ESDU (1984). The correlations were derived using data from a
number of different geometries of staggered arrays, with adaptations by HTFS
for low Reynolds number flow and for in-line arrays. This is the recommended
method.
The Wolverine method is a simpler method published by a specific
manufacturer. It is provided only for the convenience of users who have a
specific need to use this method.
The Rabas et al (SM17) (1981) correlation was used in earlier versions of
TASC and is provided here so that comparisons with the current
recommended method can be made if necessary.
 AirCooled: Exit Pressure Recovery Coefficient
Usually for use with an induced draught exchanger fitted with a fan exit
diffuser.
See HTFS Handbook Sheet AM21.
Default value = 0.0
 AirCooled: Fan Guard Pressure Loss Coefficient
Enter the number of velocity heads lost through the fan guard.
The velocity is based on the area of the fan ring.
See HTFS Handbook Sheet AM21.
Default value = 0.0
 AirCooled: Fan Guard Support Pressure Loss
Coefficient
Enter the number of velocity heads lost through the fan guard.
The velocity is based on the area of the fan ring.
See HTFS Handbook Sheet AM21.
Default value = 0.0
 AirCooled: Include Outside Radiation Heat
Transfer
Select Yes if you wish to include X-side radiation calculations in your run.
This option is applicable to the following conditions:
· The radiation calculations will be performed if you have a gas stream
with single component of CO2 or H2O or multi-components containing CO2
and/or H2O. The method is only applicable to a gas stream at temperature
greater that 400°C.
· If radiation calculations are switched on and the gas temperature is less
than 400°C, then AirCooled issues a warning to indicate that radiation has
been switched off.
· Radiation calculations are not applicable to dry or wet air. AirCooled
issues a warning if radiation calculations are switched on.
· If the properties of the X-side stream are input directly, AirCooled uses
default values for mole fractions of CO2 (0.12) and H2O (0.10) and continues
the calculations. AirCooled will issue a warning to indicate this. If the gas
stream does not contain CO2 or H2O, then you need to switch the radiation
calculations off.
· If radiation is switched on for X-side stream with single or multi-
component containing no CO2 or H2O, then radiation is switched off and a
warning is issued.
References:
Radiation calculations for plain tubes: Berman (1978)
Radiation calculations for finned tubes: HTFS Handbook Sheet RM19
 AirCooled: Mole Fraction of Radiating Gases in
Flue Gas
An input for the radiation heat transfer calculation in flue gas economizers
allows the user to specify the mole fraction of radiating gas (CO2, H2, etc.), in
the flue gas. The value of the input mole fraction will affect the radiation heat
transfer coefficient.
 AirCooled: Enhancement type
The following options are available for the tube side enhancement type. These
let you modify or replace program-calculated values for tube side heat
transfer coefficients and pressure gradients.
(No Enhancement)
Enhancement Factors
j and f input
Twisted Tapes
Performance Data
hiTRAN Wire Matrix

If required, select one of the available Enhancement Types.

 AirCooled: Format of input data
This option lets you select to scale the program-calculated Outside heat
transfer coefficients (use HTC scaling), or lets you provide alternative Outside
Performance Data, in a wide variety of possible forms, to be used instead of
program-calculated coefficients and pressure gradients.
This Performance Data can be in two basic forms, both of which permit a
dependence on flow rate to be defined. One form is to supply two data points
which can be interpolated (or extrapolated). Another is to define an
exponential curve by supplying a scaling factor and an exponent.
Flow can be defined in three ways: mass flux (mass velocity), and Reynolds
number, based on either tube OD or on hydraulic diameter.

Select the method of input for the Outside Performance Data from the
following list:
Read from databank
htc and pd per row v. mass flux points
j and f v. Re(do) points
j and f v. Re(dh) points
Nu and f v. Re(do) points
Nu and f v. Re(dh) points
Nu and Eu v. Re(do) points
Nu and Eu v. Re(dh) points
htc and pd per row v. mass flux curves
j and f v. Re(do) curves
j and f v. Re(dh) curves
Nu and f v. Re(do) curves
Nu and f v. Re(dh) curves
Nu and Eu v. Re(do) curves
Nu and Eu v. Re(dh) curves
Nusselt numbers, Colburn j factors, Euler Numbers and Reynolds numbers
may be based on either do or dh.
do is the tube outside diameter.
dh is the bundle hydraulic diameter, based on minimum flow area.
Dimensional parameters must be in pure SI units.
htc (heat transfer coefficient), is in W/m2 K
pd (pressure drop) per row is in Pa
mass flux (mass velocity) is in kg/m2 s
When an option is selected, both pressure drop and heat transfer information
must be supplied in this form.
 AirCooled: Performance Database Selection
If Read from databank has been selected for Format of Input Data, then a
list of available data will be provided from which the desired data identifier
can be selected.
This data comes from the Outside Performance User Databank. This is a flat
ASCII file containing stored performance data for outside surfaces. The file
will be named XSUSER.DAT and will be stored in the AirCooled for Windows
program directory. The file is automatically created when the first set of data
is stored, i.e., when a Data Identity has been assigned to a particular set of
outside Performance Data.
 AirCooled: Pt. 1 Flow parameter
Enter values of the flow parameter at 2 points, which correspond to the
values of the heat transfer and pressure drop parameters.
This can be:
X-side mass flux based on the bundle face area,
Reynolds number based on the outside diameter of the tube, or
Reynolds number based on the bundle hydraulic diameter,
as defined in X-side Performance Data Input.
 AirCooled: Pt. 1 Ho parameter
Enter a value of the heat transfer parameter at each point, which corresponds
to each value of the flow parameter.
This can be,
Heat transfer coefficient corrected for surface effectiveness,
Heat transfer j factor, or
Nusselt Number,
as defined in X-side Performance Data Input.
 AirCooled: Pt. 1 PD parameter
Enter a value of the pressure drop parameter at each point, which
corresponds to each value of the flow parameter.
This can be,
Mean crossflow pressure drop over one row,
Friction factor, or
Euler Number
as defined in X-side Performance Data Input.
 AirCooled: Pt. 2 Flow parameter
Enter values of the flow parameter at 2 points, which correspond to the
values of the heat transfer and pressure drop parameters.
This can be,
X-side mass flux based on the bundle face area,
Reynolds number based on the outside diameter of the tube, or
Reynolds number based on the bundle hydraulic diameter,
as defined in X-side Performance Data Input.
 AirCooled: Pt. 2 Ho Parameter
Enter a value of the heat transfer parameter at each point, which corresponds
to each value of the flow parameter.
This can be,
Heat transfer coefficient corrected for surface effectiveness,
Heat transfer j factor, or
Nusselt Number,
as defined in X-side Performance Data Input.
 AirCooled: Pt. 2 PD parameter
Enter a value of the pressure drop parameter at each point, which
corresponds to each value of the flow parameter.
This can be,
Mean crossflow pressure drop over one row,
Friction factor, or
Euler Number
as defined in X-side Performance Data Input.
 AirCooled: Ho curve Coefficient
Enter the value of the coefficient A in the heat transfer equation of the
following form, depending on the heat transfer and flow parameters selected.
 AirCooled: Ho curve Exponent
Enter the value of the exponent m in the heat transfer equation of the
following form, depending on the heat transfer and flow parameters selected.
 AirCooled: PD curve Coefficient
Enter the value of the coefficient B in the pressure drop equation of the
following form, depending on the pressure drop and flow parameters selected.
 AirCooled: PD curve Exponent
Enter the value of the exponent n the pressure drop equation of the following
form, depending on the pressure drop and flow parameters selected.
 AirCooled: HTC scaling factor
Instead of entering your own heat transfer data for the extended surface
being used, you can allow AirCooled to calculate the coefficient and then scale
it by the value entered here.
This scaling applies only to the X-side dry gas coefficient. It is applied to the
effective coefficient based on Tube Outside Diameter, which incorporates any
fin efficiency effects.
A separate scaling factor can be applied to each tube type.
This parameter was previously referred to as the Ho scaling factor.
 AirCooled: Number of elements across the
width of the bundle
Enter the number of elements across the bundle (i.e., normal to the direction
of the tube length) for specifying the Outside Inlet Distribution data.
The maximum value is 6.
 AirCooled: Number of elements along the
length of the bundle
Enter the number of elements along the bundle (i.e. in the direction of the
tube length) for specifying the Outside Inlet Distribution data.
The maximum value is 12.
 AirCooled: Outside Inlet Distribution
This facility allows you to specify a 2-dimensional Outside mass flow and/or
temperature distribution at the bundle entry. The elements of the distribution
are specified in a grid which can have maximum of 12 elements along the
tube length and 6 elements across the bundle width. An inlet Outside mass
flow or temperature distribution may be caused by the effect of adjacent
structures. (See HTFS Handbook sheet AE1)
Note that the Outside distribution is applied to a bundle and as the program
treats every bundle identically, then the distribution data will apply to all
bundles in a unit. The effect of the distribution on performance can be seen in
the Results.
As the mass flow distribution and the temperature distribution are specified
on the same grid size, then the grid dimensions must be large enough to
accommodate the more complex distribution. See example below.
The values to be entered in the mass flow distribution grid are either the flow
through each element as a percentage of the highest element flow or the flow
through each element as a percentage of the total flow through the bundle.
The values to be entered in the temperature distribution grid are simply the
temperature of the Outside stream at each element.
Example:
Suppose that we wish to model an air-cooled heat exchanger in which each
bundle is served by three fans with the first fan operating at full flow, the
second fan operating at 10% of full flow, and the third fan operating at 5% of
full flow. This is case where we have a 3 by 1 mass flow distribution grid. The
grid values can either be the flow through each element as percentage of the
highest element flow or the flow through each element as a percentage of the
total flow through the bundle:

Mass flow distribution OR Mass flow distribution

1 1

3 100 3 87.0

2 10 2 8.7

1 5 1 4.3

Note: In this case, the total Outside mass flowrate has been reduced to 0.4 of
the original value, i.e., (1.00+0.1+0.05)/3.0, and this new value must be
entered in the Process Data input form.
In addition, suppose that we have the following 2 by 2 temperature
distribution superimposed on the mass flow distribution:

Temperature distribution (deg C)

1 2

2 20 25

1 30 35

Then we need to specify both distributions in the following 6 by 2 grids.

Mass flow distribution OR Mass flow distribution

1 2 1 2

6 100 100 6 21.75 21.75

5 100 100 5 21.75 21.75

4 10 10 4 2.175 2.175

3 10 10 3 2.175 2.175

2 5 5 2 1.075 1.075

1 5 5 1 1.075 1.075

Note that mass flow distribution values entered in the first format and saved
in an input data file will always appear in the second format when the data
file is subsequently loaded into the program.

Temperature distribution (deg C)

1 2

6 20 25

5 20 25

4 20 25

3 30 35

2 30 35

1 30 35
 AirCooled: Number of Insert Types
This input applies when hiTRAN inserts are selected.
Up to three different hiTRAN inserts types (with different loop densities) can
be selected for an AirCooled tube bundle. AirCooled assumes that each insert
type occupies all tubes in a specified range of passes. All hiTRAN calculation
options require the installation of the hiTRAN wire mesh calculation library
(supplied and licensed solely by Cal Gavin Limited) which calculates tube-side
heat transfer coefficients, calculates tube-side frictional pressure drops, and
performs insert selection.
 AirCooled Start Pass for hiTRAN Insert
First pass containing this hiTRAN insert type
 AirCooled End Pass for hiTRAN Insert
Last pass containing this hiTRAN insert type
 AirCooled: hiTRAN Insert Calculation Type
Find Optimum Insert
Determine (in checking/rating mode) the hiTRAN wire insert (identified by a
50 character string) which gives the maximum tube-side heat transfer
coefficient in a specified range of passes while ensuring the tube-side
pressure drop is less than the specified maximum tube-side pressure drop. It
is assumed that the calculated hiTRAN wire insert is present in all straight
sections of tubes in the specified range of passes.
Use previous Insert
Specify that a previously determined hiTRAN wire insert is present in all
straight tube sections in a specified range of tube side passes.
Specify new Insert
Specify a hiTRAN wire insert (identified by a 50 character string) is present in
all straight tube sections in a specified range of passes.
 AirCooled: hiTRAN Part Number
This is a 50 character string that uniquely identifies a hiTRAN wire insert type
available from Cal Gavin Limited. The best insert for a given application can
be determined using the calculation or alternatively the user can specify the
part number.
 FiredHeater Liquid Fuels

Liquid fuels range from light naphthas through to heavy asphaltenic and
polymer fuel oils.
Liquid fuels require atomizing in order to burn This can be achieved simply by
pressure, but pressure atomizers are inefficient and display a poor flexibility
to rate, viscosity and density It is more usual to use a secondary fluid,
compressed air or steam, to supply the energy Although air is better in theory
as it can be regarded as part of the combustion air requirement, this has
generally been outweighed by the greater convenience of using readily
available steam. Steam also has the advantage that, being hot, it does not
chill the fuel This is important with heavy oils When using steam, between 0.1
and 0.3 kg per kg of fuel is required If air is used, then about 50% more than
this is needed.
FiredHeater: Box (Cabin) Firebox with 4 Paths –
Separated
Note: As per API 560 definition 3.61: Pass Stream = 8
FiredHeater: Box (Cabin) Firebox with 4 Paths –
Interspersed
Note: As per API 560 definition 3.61: Pass Stream = 8
 FiredHeater: Cylindrical Firebox with 6 Paths

Note: As per API 560 definition 3.61: Pass Stream = 6

FiredHeater Plain Tube
FiredHeater Solid Fin
 FiredHeater Serrated Fin
This fin type is as per Solid Fin, but the fins are serrated
FiredHeater Rectangular Studded
FiredHeater Elliptical Studded
FiredHeater Lenticular Studded
FiredHeater Chamfered Studded
FiredHeater Circular Studded
FiredHeater Rectangular Plate Fin
FiredHeater Convection Bank with 4 Paths
FiredHeater Convection Bank with 6 Paths
FiredHeater Tube Layout 30° (equilateral
triangle)
FiredHeater Tube Layout 45° (rotated square)
FiredHeater Tube Layout 60° (rotated triangle)
FiredHeater Tube Layout 90° (inline square)
 FiredHeater Gas Side Heat Transfer Versus
Pressure Drop (Convection Section)

The design considerations for the convection section are in many ways similar
to those for a multi-layer multi-pass air cooler with the added complication of
radiation
Increasing the gas velocity through a tube bank increases the heat transfer in
that bank but also increases the gas-side pressure drop across the tubes.
In common with air coolers, it is generally found that the best balance
between heat transfer and pressure drop is achieved with an equilateral
triangular pitch of around 2 diameters.
 FiredHeater Process Side Flow Arrangement
(Convection Section)

It is not always a simple matter to decide on the process side flow pattern
from row to row of the convection section
The number of parallel paths through a convection coil is determined by
process-side velocity and pressure drop requirements, while the width of the
duct, and therefore the number of tubes it can accommodate is a function of
flue gas velocity and pressure drop requirements

See also:
Regular Tube Banks
Irregular Tube Banks
Waste Heat Recovery Schemes
 FiredHeater Gas Side Fouling (Convection
Section)

All extended surfaces will foul - even in a clean gas fired environment,
atmospheric and refractory dust together with the oxidation products of tubes,
burners and supports will gradually accumulate and impair heat transfer by
bridging over the gaps between fins Deposits are normally removed by soot
blowers in a heavily fouling (i.e. ash-laden) environment, and by means of
portable air lances for surfaces needing cleaning only at periodic shutdowns.
Experience has shown that soot blowers and air lances generally only
penetrate about 4 rows into the bank High pressure water-jetting provides a
more thorough but messy and time-consuming method of cleaning.
As fouling occurs, the general effect is to reduce heat fluxes and therefore
metal and fin temperatures, but to increase the gas temperatures Tube
support design therefore needs to be carefully considered for fouling duties.
Spaces may be left within the convection bank for cleaning or tube
withdrawal, or to provide the flexibility to add extra tubes at a later date (e.g.
for an anticipated uprating or change of duty).
 FiredHeater Low Exhaust Gas Temperature
(Convection Section)

On heaters where a very high efficiency, and therefore a low exhaust

temperature, is sought, care must be taken with regard to the dew point of
the flue gases, particularly if high-sulfur fuels are in use
To avoid very cold surfaces at the cold end of the heater, coils handling fluids
which are very cold at the inlet are often arranged wholly or partially co-
current with the gas.

See also
Exhaust Gas Temperature (Design Considerations)
 FiredHeater Regular Tube Banks

In the simplest layout the number of tubes per row is equal to the number of
parallel paths Next simplest is the situation where the number of tubes per
row is an exact multiple of the number of parallel paths The process fluid may
also flow through all the tubes of a bank in parallel - an arrangement common
in Waste Heat Boilers Arrangements such as those described above are called
regular, and calculations can be made on a row by row or even on a whole-
bank basis.
 FiredHeater Irregular Tube Banks

More complex, or irregular, arrangements are also used in which the parallel
paths do not have the same number of tubes in each row. Calculations on
such tube banks may require a tube by tube approach if detailed knowledge of
the conditions at each tube ia required.
 FiredHeater Solid Fuels

Solid fuels are not normally burned in process heaters.

 FiredHeater Natural Draught Burners

The pressure loss across a natural draught burner is typically 10 to 25 mm

water gauge (1 to 2.5 mbar), limited by the available draught in the heater
This pressure drop determines the amount of energy available for mixing the
air and fuel
The air flow, which is typically 10-20% above stoichiometric for the type of
natural draught burner used on process heaters (compared to typically 5-10%
for a forced draught burner ), must also be controlled using louvers or air
doors at the burner and this consumes part of the limited pressure energy
available
Because the amount of available energy is quite low, natural draught flames
tend to be longer, of lower intensity and more ragged than forced draught
ones. Process heater natural draught burners are also limited to around 8 MW
heat release because there is insufficient energy to provide satisfactory
mixing in a larger flame.
 FiredHeater Forced Draught Burners

With a forced draught burner, the burner designer is free to select whatever
pressure drop they require, subject to economic constraints Figures up to 200
mm water (20 mbar) are quite common Forced draught flames are therefore
more intense, shorter and more controllable (particularly at turn-down) than
natural draught ones.
The air rate may be controlled at the fan inlet so no extra resistance is placed
in front of the burner In general, a forced draught flame can be run with less
excess air (typically 5-10% above stoichiometric for the type of burner used
on process heaters) than a natural draught one (typically 10-20%), and this
air ratio can be maintained at turned down conditions
Forced draught burners are therefore more efficient, but at the expense of
providing and running a fan A forced draught fan is of course essential when
an air pre-heater is fitted, although this is sometimes used merely to supply
plenum air to a burner of essentially natural draught design.
 FiredHeater Firebox Aspect Ratio

With an upshot heater, the aspect ratio - that is the ratio between the height
and the width or diameter of the firebox is generally optimal at about 2.5 to 1
At less than 2 to 1, the flame tip is too high in the firebox; there is a danger
of overheating the roof or shock tubes and the radiant efficiency is low
Above 3 to 1 the top of the heater is too remote from the flame and the
firebox is too narrow - leading to a high peak heat flux and possible flame
impingement on the tubes
 FiredHeater Flame and Firebox Height

The height of the flame should not exceed two-thirds the height of the firebox
and adequate lateral clearance must be provided between the edge of the
flame and the front face of the tubes.
 FiredHeater Firebox Heat Losses

Between 1% and 2% of the heat input to the firebox is lost, mainly through
the walls Radiant heat transfer calculations are often simplified by assigning a
fixed value to this loss, sometimes referred to as radiation loss.
Heaters are usually designed such that the outside casing temperature is in
the region of 350 K (77°C) to 370 K (97°C) This temperature range or the
need to protect structural components will determine the thickness of the
refractory lining.
 FiredHeater Firebox Heat Flux

The heat flux to the radiant coil is limited by the requirement not to overheat
the tube metal or in the case of heat sensitive fluids the inside surface film
In the case of vaporizers, it is also important to consider the flow regime
inside the tubes - in particular to avoid dryout in regions of high heat flux
For refractory-backed tubes, the average heat flux in the radiant section is
usually limited to 32 kW/m2 (10000 Btu/sqft/hr) For central tubes fired on
both sides, this is increased to 48 kW/m2 (15000 Btu/sqft/hr) and in Radiant
Wall heaters where the heat flux is exceptionally even to as much as 64
kW/m2 (20000 Btu/sqft/hr).
 FiredHeater Heat Input from Fuel

The heat input from combusting a fuel is determined by its calorific value, and
any sensible heat due to the fuel(s) and/or oxidant(s) being pre-heated.
The Lower Calorific Value is the heat released in combusting fuel and oxidants
initially at 25 deg C, and then cooling the combustion products back down to
25 deg C Lower, in this context, means that any water in the flue gases is
assumed not to condense, but remain in the gaseous phase.
If either the fuel or oxidants are input above 25 deg C, this represents an
additional sensible heat input The Heat Balance output in the program gives
the heat input based on lower calorific value alone, and also that allowing for
the sensible heat of fuel and oxidants relative to 25 deg C
For completeness it also gives the heat input allowing for fuel and air heating
from ambient, which can be regarded as the some of the heat from the fuel
calorific value, and the heat used to preheat the fuel and oxidant.
Fuel and oxidant pre-heats, from ambient to their inlet temperature(s) are
also given separately.
If steam is used to atomize the fuel, then the steam heat input (based on the
difference between water vapor at 25 deg C and its inlet temperature) is both
given separately, and included in the total heat inputs.
 Physical Property Data Aspen Property Method
- Process Type - CHEMICAL
WILSON
NRTL
UNIQUAC
WILS-LR
WILS-GLR
WILS-HOC
NRTL-HOC
UNIQ-HOC
WILS-RK
NRTL-RK
UNIQ-RK
WILS-2
NRTL-2
UNIQ-2
PENG-ROB
RK-SOAVE
WILS-HF
ELECNRTL
ENRTL-HF
UNIFAC
UNIF-DMD
UNIF-LBY
 Physical Property Data Aspen Property Method
- Process Type - COALPROC
SOLIDS
PR-BM
RKS-BM
 Physical Property Data Aspen Property Method
- Process Type - COMMON
BK10
CHAO-SEA
ELECNRTL
IDEAL
NRTL
PENG-ROB
POLYNRTL
PSRK
SOLIDS
SRK
STEAMNBS
UNIFAC
WILSON
WILS-GLR
UNIQUAC
 Physical Property Data Aspen Property Method
- Process Type - ELECTROL
ELECNRTL
ENRTL-HG
ENRTL-HF
PITZ-HG
PITZER
 Physical Property Data Aspen Property Method
- Process Type - ENVIRON
ELECNRTL
NRTL
PRMHV2
PRWS
PSRK
RKSMHV2
RKSWS
SR-POLAR
UNIQUAC
WILSON
 Physical Property Data Aspen Property Method
- Process Type - GASPROC
PR-BM
RKS-BM
RKSWS
PRMHV2
RKSMHV2
PSRK
SR-POLAR
ELECNRTL
PENG-ROB
RK-SOAVE
 Physical Property Data Aspen Property Method
- Process Type - HF-ACID
ENRTL-HF
WILS-HF
 Physical Property Data Aspen Property Method
- Process Type - METAL
SOLIDS
ELECNRTL
 Physical Property Data Aspen Property Method
- Process Type - OIL-GAS
PR-BM
RKS-BM
 Physical Property Data Aspen Property Method
- Process Type - PETCHEM
CHAO-SEA
GRAYSON
PENG-ROB
RK-SOAVE
WILSON
NRTL
UNIQUAC
 Physical Property Data Aspen Property Method
- Process Type - POLYMER
POLYFH
POLYNRTL
POLYSAFT
POLYSL
POLYSRK
POLYUF
POLYUFV
POLYPCSF
PNRTL-IG
 Physical Property Data Aspen Property Method
- Process Type - POWER
PR-BM
RKS-BM
STEAMNBS
STEAM-TA
 Physical Property Data Aspen Property Method
- Process Type - REFINERY
BK10
CHAO-SEA
GRAYSON
PENG-ROB
RK-SOAVE
 Physical Property Data Aspen Property Method
- Process Type - SYNFUEL
PR-BM
RKS-BM
BWR-LS
 Physical Property Data Aspen Property Method
- Process Type - WATER
STEAMNBS
STEAM-TA
 Physical Property Data Aspen Property Method
- Process Type - Chemical systems
NRTL
UNIF-LL
UNIQUAC
 Physical Property Data Aspen Property Method
- Process Type - Hydrocarbon systems
PENG-ROB
LK-PLOCK
SRK
NRTL
 Shell&Tube Vibration: Natural Frequency
Natural frequency is an inherent characteristic of a structure and is a primary
parameter in vibration analysis. A heat exchanger tube in principle has an
infinite set of vibration frequencies, but only the lowest natural frequency is
usually important, and this is all that Shell&Tube considers.
In a flow-induced vibration analysis, it is important to recognize that a tube
vibrates as a whole and therefore the natural frequency of the entire tube is
required.
Wherever possible, Shell&Tube calculates the tube natural frequency using an
exact solution of the equations of motion. The natural frequency of a tube is
primarily influenced by the distance between adjacent supports, referred to as
the span length. The exact solution applies when the mid-spans of a tube are
of equal length and there are single straight spans in both end zones of the
tube. The two end-spans can be of a different length from the mid-span and
different from each other. In all other circumstances, e.g. U-tubes, the
simpler “Dominant Span” method is used. In this method the natural
frequency of each span is calculated separately and the tube frequency is set
to the lowest value of the span frequencies. This approach leads to a
conservative estimate of the critical velocity for onset of fluid-elastic
instability.
See also:
Acoustic Resonance
 Shell&Tube Vibration: Entry conditions
The velocity distribution on the first (top) tube row at the exchanger inlet is
very much dependent on the entry conditions. The flow is dictated by the
nozzle type and presence or absence of an impingement plate. This is defined
in the Shell&Tube input on nozzles.
In general, the vibration analysis applies the bundle entrance velocity to the
top tube row. It is possible to specify a support under the inlet nozzle. This
support only affects the top tube row. For TEMA J, I, G,and H shells the
calculations assume a "zero" cut baffle on the inlet and/or outlet nozzle
centre-line.
See also:
Vibration in U-Tube Bundles
 Shell&Tube: Open Distances with Pass Details
Specification
When the option Specify Pass Details is used for the Tube Layout, default
inputs are shown for all four open distances, at the top, bottom, left, and right
sides of the bundle. If a default cannot be evaluated (for example, tubes are
to be removed under a nozzle, but the nozzle diameter has not been
specified), the corresponding open distance will appear as a missing
(mandatory) input. If you subsequently specify a nozzle diameter, the
corresponding open distance default will appear.
The four open distances, together with pass-partition lane widths and the tube
row and column spacings determined by the tube pitch and tube pattern,
determine the number of rows and columns of tubes. If you specify an open
distance different from the default, then the open distance on the opposite
side and the number of tube rows and columns (on the Pass Details input
form) will also be revised if necessary. Alternatively, you can specify a
number of rows or columns of tubes different from the default. This will cause
a change in the defaults for open distances.
If the number of tube rows shows a non-integer value by default, then the top
and bottom open distances have both been specified, but are inconsistent.
Change (or reset to default) one of the open distances, or change the
horizontal pass partition lane width. Similarly, for a non-integer number of
tube columns, an open distance at a side or the vertical pass-partition lane
width should be amended.
See also:
Tube Bundle Layout: How it is Calculated
Bundle Layout
Shell&Tube Horizontal Shell Side Reboiler
Picture
Shell&Tube Vertical Tube Side Reboiler Picture
Shell&Tube Example 1. Vertical Thermosiphon
Shell&Tube Example 2. Horizontal Thermosiphon
 Shell&Tube Vibration: Geometry Factors
The risk of vibration of a tube depends on the exchanger geometry, and on
the position of the tube within the bundle.
Key factors are:
Shell Types Considered In Shell&Tube
Tube Rows Examined
Entry conditions
U-Tube Bundles

See also:
Shell Types Considered
 Shell&Tube Vibration: Acoustic Resonance
Sound (acoustic) waves can be propagated inside the cavity formed by the
shell of the heat exchanger.
The parameters which determine the acoustic resonance frequency are:
1. Shell diameter increase to decrease acoustic resonance frequency
2. Velocity of sound increase to increase acoustic resonance frequency
The velocity of sound depends on the phase of the shell side fluid and its
properties. In fluids the velocity of sound is usually so large that the acoustic
resonance mechanism is not usually a problem. It may be more relevant to
gases and mixtures of gases and liquids.
Principle features of acoustic resonance are:
1) The main consideration is whether there is a “Lock-In” Effect with the
Vortex Shedding and/or Turbulent Buffeting frequencies
2) Damage to tubes may not occur, but the NOISE may be unacceptable.
3) There can be many acoustic resonance frequencies. Shell&Tube considers
only the lowest frequency (the first mode)
4) Acoustic baffles may be inserted inside the tube baffle space to prevent
acoustic resonance
Shell&Tube uses the Liquid Compressibility (Isothermal Modulus of Rigidity) of
water in the calculation of the velocity of sound for liquid and two-phase
streams. This approximation for non-water streams is usually acceptable.
Refer to HTFS Handbook Sheet VM5 for more information

See also:
Vortex Sheading
 Shell&Tube Vibration: Vortex Shedding
Vortex shedding is the phenomenon caused by the periodic shedding of
vortices as the fluid flows over a non-streamlined object such as a heat
exchanger tube.
Principle features are:
Wake oscillates with frequency proportional to flow velocity.
Resonance will occur when vortex shedding frequency approaches tube
Natural Frequency or Acoustic Resonance under the “Lock-In” Effect
Liquid flow - may cause damage especially if number of spans with locked on
vortex shedding is large
Gas flow - This rarely causes tube damage but be aware of Acoustic
Resonance
The basic equation used to determine the vortex shedding frequency is:
fv = St.U / d
Where:
fv Vortex shedding frequency
U Flow velocity
d Tube outside diameter
St Strouhal number
The Strouhal number is non-dimensional. It is calculated in Shell&Tube for
the inlet, midspace and outlet regions for each of the Tubes Considered in the
Vibration Analysis and is listed in the Table of Vibration Predictions. The
Strouhal number is derived from experiment. The main parameters it depends
on are:
a. Tube layout
b. Tube outside diameter
c. Tube pitch
The “Lock-In” Effect is checked within Shell&Tube and the related frequency
ratios are reported in the Table of Vibration Predictions of the full Vibration
Output
Predicted problem areas are indicated in the Shell&Tube output where the
ratio is bracketed by asterisks (e.g. *0.93*).

See also:
Turbulent Buffeting
 Shell&Tube Vibration: Turbulent Buffeting
Turbulent buffeting occurs when a body is placed in a turbulent flow field and
the forces on the surface of the body are changed rapidly with time and
position. Turbulent buffeting is an extremely complex mechanism mostly due
to its random nature, while other flow induced mechanisms are basically
deterministic. The phenomenon operates over nearly the entire range of fluid
parameters, whereas other mechanisms are limited to the parameter ranges
that produce resonance or instability. Thus turbulent buffeting is different in
nature to other Vibration Mechanisms.
If the variation in force is well correlated (changes in force magnitude and
direction along a significant length of tube are in phase) tube vibration may
result as a cause of the “Lock-In” Effect of the turbulent buffeting frequency
approaching the Natural Frequency or Acoustic Resonance.
The main parameters involved in the calculation of the turbulent buffeting
frequency are:
Tube outside diameter
Flow velocity
Longitudinal pitch (allowing for the local flow direction)
Transverse pitch (allowing for the local flow direction)
Important features of turbulent buffeting are:
All flows have random pressure fluctuations
Random pressure on tube causes random vibration
Single-phase: turbulence
Two-phase: turbulence plus density fluctuations
Effects are remorseless. Holes due to wear at tube supports will occur at some
time (e.g. 10 years)
Turbulent buffeting is not thought to be such an important mechanism of
vibration damage unless the “Lock-In” Effect occurs
The “Lock-In” Effect is checked within Shell&Tube and the related frequency
ratios are reported in the Table of Vibration Predictions of the full Vibration
Output.
Predicted problem areas are indicated where the ratio is bracketed by
asterisks (e.g. *0.93*).

See also:
`Lock-in' Effect
 Shell&Tube Vibration: `Lock-In' Effect
The “lock-in” effect is the phenomenon whereby an excitation frequency
coincides with a characteristic frequency of a body to cause a large amplitude
of vibration. That is a frequency resonance has occurred.
Important notes:
This frequency matching should be avoided in order to prevent damage due to
vibration
The “lock-in” effect occurs across a range of flow velocities (see below) and
may be “tuned out” of the system, by going to either higher or lower flows, or
using tube supports giving either higher or lower natural frequencies
There may be more than one resonance over the operating range of the heat
exchanger, due to higher natural frequencies. (Shell&Tube considers only the
fundamental (lowest) frequency)
A more serious form of vibration mechanism is the Fluid-Elastic Instability,
which is not a ‘lock-on’ mechanism, and thus cannot be passed through.
Unlike other vibration mechanisms, lower tube natural frequencies or higher
flow rates only make it worse.
The “lock-in” effect is checked within Shell&Tube for:
Excitation frequency: Vortex Shedding, Turbulent Buffeting
Characteristic frequency: Natural Frequency, Acoustic Resonance
“Lock-in” occurs when the excitation frequency comes within 20% of the
characteristic frequency. For the Shell&Tube analyses this is reported in the
Table of Vibration Predictions of the full Vibration Output.
0.8 < FV / FN < 1.2
0.8 < FV / FA < 1.2
0.8 < FT / FN < 1.2
0.8 < FT / FA < 1.2
Where:
FV Vortex Shedding
FT Turbulent Buffeting
FN Natural Frequency
FA Acoustic Resonance
Predicted problem areas are indicated where the ratio is bracketed by
asterisks (e.g. *0.93*).
Triple coincidence, when the frequencies of three mechanisms coincide, is a
potentially serious problem which you should take steps to avoid.

See also:
Triple Coincidence
 Shell&Tube Vibration: Vibration Damping
Energy is dissipated as a heat exchanger tube vibrates. This energy
dissipation causes the vibration to be damped and so limits the amplitude of
the oscillation. Damping effects are extremely complex and individual tubes
can have very different characteristics.
The main mechanisms of damping are:
Fluid damping is caused by viscous and pressure drag as the tube moves
relative to the fluid
Baffle support damping is caused by friction due to impacting and sliding of
the tube at the baffle hole resulting from the inevitable clearance
Squeeze film damping is the dissipation of energy due to the periodic
displacement of fluid from the tube/baffle gap as the tube vibrates
Material damping is the natural energy dissipation which occurs when the
tube is flexed
Important aspects:
There is a single value of damping associated with a tube over its entire
length. Damping cannot be assessed for the tube’s individual spans or regions
(inlet, midspace, and outlet).
All damping mechanisms may act at the same time
The fluid phase may determine the dominant contribution (e.g. baffle support
for gases)
The fluid phase may determine the dominant contribution (e.g. baffle support
for gases).
For Fluid-Elastic Instability, in particular, damping must be considered. The
overall level of damping can be indicated by a term called the logarithmic
decrement (L DEC in the Tables of Fluid-Elastic Instability Assessment).
Shell&Tube initially considers three general levels of damping defined by log
decrements of 0.1 and 0.03, 0.01. The highest value, 0.1, reflects heavy
damping; the value of 0.03 serves as a medium value, while 0.01 would
represent light damping. Typical log decrements for a single phase liquid
stream on the shell side tend to be close to 0.1 (heavy). For gases, typical
values are closer to 0.03. Two-phase fluid damping is more difficult to
analyze, but may be assumed to lie between these ranges.
Shell&Tube calculates a typical damping level in the ‘Estimated’ table of the
Tables of Fluid-Elastic Instability Assessment. Shell&Tube methods are based
on the careful and extensive comparisons of numerous research studies
taking into account the mechanisms described above. This estimated damping
value may apply to the majority of tubes within the heat exchanger.

See also:
Fluid Elastic Instability
 Shell&Tube Vibration: Fluid-Elastic Instability
Fluid-elastic instability (or fluid-elastic whirling) is perhaps the most
important of the mechanisms of flow induced vibration. Damage caused by
fluid-elastic instability can be severe and result within minutes. Unlike other
Vibration Mechanisms this is not a resonant vibration and ultimately tube
movement is only limited by contact with other tubes or mechanical
constraints. For fluid-elastic instability the phenomenon occurs above a
critical velocity rather than a resonant frequency.
Essential parameters of fluid-elastic instability are:
1. The critical flow velocity determines the point of instability
2. The level of Damping for the tube
3. The Natural Frequency for the tube
4. Heat exchanger geometry
5. Fluid phase and properties
Essential notes:
Fluid-Elastic Instability must be avoided. The results from other mechanisms
(e.g. Acoustic Resonance) may be acceptable, but fluid-elastic instability will
fail.
Fluid-elastic instability applies to the entire tube. It cannot be assessed for
the tube’s individual spans or regions (inlet, midspace, and outlet).
Care needed during non-standard operation (e.g. start-up / shutdown)
Shell&Tube assesses fluid-elastic instability by comparing the actual mass flow
into the exchanger with the critical mass flow for onset of instability (W/WC in
the Tables of Fluid-Elastic Instability Assessment). When the ratio of actual to
critical mass flow is greater than 1.0, Shell&Tube identifies this with asterisks
(*) in the output.
The calculations for fluid-elastic instability are highly dependent on Damping,
which may vary throughout a heat exchanger. The level of damping can be
indicated by a term called the logarithmic decrement (L DEC in the Tables of
Fluid-Elastic Instability Assessment).

See also:
Avoiding Vibration
 Shell&Tube Vibration: Vibration Damage
Flow-induced vibration is usually revealed by leaking tubes and/or tube-
tubesheet joints. Other symptoms include loud noises or an increase in shell
side pressure loss.
An important point to remember is that the cure for one of the Vibration
Mechanisms may enhance the risk of another type of damage. Hence a careful
analysis is required. Furthermore, vibration damage of one tube may result in
accelerated damage to another; thus compounding the problem.
Damage within a heat exchanger resulting from vibration may present itself
in a number of ways:
Fatigue due to repeated bending. Since the continuous vibrations cause
stresses then the tubes become prone to stress corrosion.
Repeated impact between adjacent tubes at mid-span; flat spots occur leading
to thinning of the tube walls with eventual splitting. This is termed “collision
damage”.
Cutting at the baffles due to repeated impact between tube and baffle. This
may happen if the baffles are thin and/or harder material than the tubes
and/or if there is a large baffle-tube clearance and/or if the drilled holes have
sharp edges. The tubes thin and eventually split, or completely sever, in
extreme cases. This is termed “baffle damage”. Potential problems can be
seen during cleaning.
Cutting at the tube-hole edges at the inner tubesheet face due to repeated
impact between tube and tubesheet.
Loosening of roller expanded tube-tubesheet joints, with and without
expansion grooves. Failures in welded tube-tubesheet joints have also been
recorded.
Excessive acoustic noise. This can sometimes lead to vibration of the entire
shell. Severe “rattling” of tubes may indicate problems.
High shell side pressure drop. Since the vibration of the tubes requires energy
input from the flowing stream, the shell side pressure drop increases as the
vibrations increase. Sudden increase in this pressure drop is an indication of
the impending damage due to the vibrations.
Fretting wear is the deterioration of the tube due to the collision between
tube-to-tube (collision damage) or tube-to-baffle hole (baffle damage).
Vibration-induced fretting wear is second only to corrosion as a cause of heat
exchanger failures.
See also
Avoiding Vibration
 Shell&Tube Vibration: Avoiding Vibration
Some general comments can be presented in order to avoid vibration
problems.
The main aspects relating to vibration reduction are:
· Reduce tube unsupported length - so increasing Natural Frequency
· Reduce crossflow velocity - so reducing energy given to tube

Unfortunately these two requirements often conflict while the heat transfer
and pressure drop specifications still need to be satisfied. Using Shell&Tube it
is a simple matter to explore how changes to the heat exchanger design affect
the vibration response.
To reduce the tube unsupported lengths, you could
· Reduce baffle pitch
· Reduce end lengths
· Add Intermediate supports
· Use ‘No-tubes in window’
· Use Rod-baffles

To reduce the crossflow velocity, you could

· Increase baffle pitch
· Increase bundle-shell clearance
· Use double segmental baffles
· Use a split-flow exchanger, such as a J shell
· Use an axial flow exchanger

In general, if there is spare heat transfer and pressure drop capacity you
could
· Reduce baffle pitch
· Reduce end lengths
· Change baffle type
· Remove some tubes

If heat transfer and pressure drop are near their limits, you could
· Change shell type
· Use a ‘No-tubes in window’ design

See also
Vibration Damage
Avoiding Vibration - Recommended Practice
Avoiding Fluid-Elastic Instability
Avoiding Vortex Shedding Resonance
Avoiding Turbulent Buffeting
 Shell&Tube Vibration: Avoiding Vibration -
Recommended Practice
Recommended practice for avoiding vibration can be divided into the following
sections:
Avoiding Vibration at the Design Stage
Avoiding Vibration during Manufacture
Avoiding Vibration during Operation
These tips are not exhaustive. The solution to an individual problem may
require detailed examination and access to expert advisors.

See also
Avoiding Vibration
 Shell&Tube Vibration: Shell Types Considered
The Shell&Tube flow-induced vibration analysis covers all TEMA shell types
and also Multi-tube Hairpin units with segmental baffles.
The vibration analysis is not currently performed for:
· Rod-baffled units, of any shell type. (Rod baffles are designed to reduce
the risk of vibration by causing axial flow, rather than crossflow; crossflow
must occur at inlet, how ever, and high velocities there should still be
avoided.)
· Other axial flow exchangers (i.e., all unbaffled units, except X shells)
See also:
Tube Rows Examined
AirCooled: Fan Configuration – Forced
AirCooled: Fan Configuration – Induced
AirCooled: Bundle type - Inline
AirCooled: Bundle type - Staggered - even rows
to right
AirCooled: Bundle type - Staggered - even rows
to left
AirCooled: Bundle type - Staggered - extra
tubes in odd rows
AirCooled: Bundle type - Staggered - extra
tubes in even rows
 AirCooled: Tube (Material Type)
Select from the drop down list the required tube material type.
If you specify a material designator for the tube material, the program
retrieves the thermal conductivity of the tube from its built-in databank.
However, if you have a tube material that is not in the databank, you can
specify the thermal conductivity of the tube material.
 AirCooled: Enhancement Factors
The following inputs are available when tube side Enhancement Type
Enhancement Factors is selected:
Starts at pass
Stops at pass
Heat Transfer Coefficient Factor
Frictional Pressure Gradient Factor
 AirCooled: j and f input
The following inputs are available when Enhancement Type j and f is
selected:
Starts at pass
Stops at pass
Reynolds number
Heat transfer j factor
Frictional f factor
 AirCooled: Twisted Tapes
The following inputs are available when Enhancement Type Twisted Tapes is
selected:
Starts at pass
Stops at pass
Twisted tape thickness
180 Degree twist pitch
 AirCooled: Performance Data
You can perform calculations on exchangers with some form of enhancement
not explicitly modeled by AirCooled if you supply Performance Data (Friction
Factors and Colburn Factors). From this data, the program can calculate
pressure losses and heat transfer coefficients.
This is most likely to be useful for tube side enhancements, such as tube
inserts. Such Performance Data relate to single phase streams. Use for two-
phase streams is not recommended.
For tube side:
· Select Enhancement
· Enter an identification for the Enhancement
· Enter sets of
– Reynolds Numbers
– Colburn Factor
– Friction Factor
You should not specify performance data for enhanced surfaces such a Twisted
Tape Inserts for which AirCooled already contains methods.

Reynolds Numbers
A list of Reynolds Numbers is used as part of the AirCooled performance data
table.
The Reynolds Numbers should cover the range of values expected. This can be
estimated by running an initial AirCooled case without performance data.
You can provide data up to 16 Reynolds Numbers, but fewer are often
adequate. The Reynolds Numbers can be in any order, but no two should be
the same. Regions of laminar, transitional, and turbulent flow can be defined
in the table. AirCooled will interpolate the data on a log-log basis. It can also
extrapolate, but this is less reliable.
AirCooled uses the supplied data in the form of:
Re = [mass flux]*[hydraulic diameter] / [viscosity]
Where the mass flux and hydraulic diameter are based on an empty tube or
channel (for tube side flow, the hydraulic diameter is the tube inside
diameter).

Colburn Factor
For each Reynolds Number in an AirCooled performance data table, enter an
associated heat transfer factor (currently the Colburn j factor). AirCooled uses
the supplied data to calculate the local heat transfer coefficient in the form of:
heat transfer coefficient = Cj * [mass flux]*[specific heat]*[Prandtl
Number]^-2/3
Where the mass flux is based on an empty tube or channel. For shell side
flow, it is that for axial flow within the bundle.
The relation used to generate the Colburn Factor data is assumed to be
dependent only on Reynolds Number, not Prandtl Number. If your Cj
relationship includes a dependence on Prandtl Number, you can use an
average value of Prandtl Number based on an initial AirCooled run without
performance data.

Friction Factor
For each Reynolds Number in an AirCooled performance data table, enter an
associated friction factor. The definition of the friction factor is:
Pressure Gradient = 2 * f * [mass flux]^2 / ([density]*[hydraulic diameter])
Where the mass flux and hydraulic diameter are based on an empty tube or
channel (for tube side flow, the hydraulic diameter is the tube inside
diameter).
 FiredHeater Waste Heat Recovery Schemes

Sophisticated heat recovery schemes may involve different parts of the

convection bank handling different process fluids - the most common
additional fluids being steam and water It should be noted that only the
primary or main heat load can be controlled by varying the heat input to the
furnace - all the other coils will achieve a heat load dependent on the amount
of waste heat that this makes available with the prevailing conditions of
flowrate, fouling, excess air etc.

See also:
Waste Heat Boilers (Principal Features)
 Shell&Tube Vibration in U-Tube Bundles
U-Tube bundles (Rear End Head Type= U) require special attention under a
vibration analysis.
Important notes are:
The unsupported span is the total length of the U-tube portion, determined
by:
U-Tube Shortest Leg Length = Shortest portion of U-tube between baffle and
bend.
U-Tube Longest Leg Length = Longest portion of U-tube between baffle and
bend
The radius of the U-tube is determined by the bundle geometry.
All these items are now automatically calculated from other input data
The unsupported span for the Tubes Considered in Vibration Analysis for U-
tubes is quoted in the Table of Vibration Predictions
The baffle geometry (i.e. single or double segmental, cut percentage and
orientation) influences the U-tube geometry
A blanking baffle (full circle baffle support) is available for U-tubes
You can specify the number of supports on the U-bend explicitly, both with
Tubes-in-Window and without
Intermediate supports can be separately specified for the straight tube
(endlength) adjacent to the U-bend
For design purposes the flow from the inlet nozzle should not impinge directly
onto the U-bend
It is advisable to design the U-bend region so that flow velocities are as low as
practicable. Provision of extra tube support should not be a justification for
using a higher than necessary fluid velocity in this area, since the gain in
overall heat transfer will be small and the risk of producing vibration large.

See also:
Natural Frequency
 Shell&Tube Vibration: Triple Coincidence
In assessing the Shell&Tube results for flow induced vibration a condition
known as "triple coincidence" should be looked for. Steps should be taken to
avoid this occurrence.
“Triple coincidence” is when a single tube suffers two (or more) Vibration:
'Lock-In' Effects on the same location along its length (for example: FV/FN
and FT/FN resonance at the inlet for the first tube row in the bundle). In this
condition the tube is being excited by two vibration mechanisms at the same
time and at the same location.
Vibration calculation methods do not yet model any interaction of vibration
mechanisms. It is strongly recommended that triple coincidence is avoided.

See also:
Vibration Damping
 Shell&Tube Vibration: Avoiding Vortex
Shedding Resonance
Alter the vortex shedding frequency by changing (increasing or decreasing)
the flow velocity
Alter the tube natural frequency (increase or decrease) by changing the span
lengths or the tube diameter. Changing the tube wall thickness has almost no
effect.
Increase the damping. This will reduce the amplitude of any vibration which
does occur, and therefore render it less damaging.

See also
Avoiding Turbulent Buffeting
 Shell&Tube Vibration: Avoiding Turbulent
Buffeting
Reduce the excitation force due to the turbulent flow by reducing the flow
velocity
Increase the tube natural frequency by shortening the span lengths (for
example by introducing intermediate support plates between baffles) or by
increasing the tube diameter. Note that increasing the tube wall thickness has
almost no effect.
Increase damping by reducing the clearances between tube and baffle.

See also
Vibration Analysis: Overview
 Shell&Tube Vibration: Avoiding Vibration at the
Design Stage
Make certain all possible duties are investigated: plants are often operated at
different temperatures and pressures, even with different fluids, for example
during catalyst reduction or during cleaning. Designers should note that many
units are operated at flows beyond that specified. When plant operation is
changed or up-rated, it will be necessary to have the heat exchanger design
re- examined.
Ensure that the design is satisfactory for conditions encountered during start
up and shut down: some failures occur because of prolonged operation at a
critical condition during part load.
Ensure that heat exchangers are included in all hazard/operability studies: in
this way abnormal operation will be routinely considered.
To produce designs with a low susceptibility to vibration, single segmental
baffles should not be used. Instead to reduce cross flow velocities, double
segmental baffles or J-shells should be used. In extreme cases designs with
no tubes in the window or cross flow units should be used. These measures
should be used in combination with low fluid velocities.
U-tube designs: avoid having the flow from the inlet nozzle impinge directly
onto the bend.
U-tube designs: consider the provision of supports by the use of stiffening
bars in the U-bend section. This alters the natural frequency. This can be
conveniently done with square and rotated square tube layouts, but is difficult
with triangular layouts.
U-tube designs: it is advisable to design the U-bend region so that flow
velocities are as low as practicable. Provision of extra tube support should not
be a justification for using a higher than necessary fluid velocity in this area,
since the gain in overall heat transfer will be small and the risk of producing
vibration large.
Ensure that inlet nozzles are not undersized: the use of perforated
impingement plates is sometimes possible to avoid high local impingement
velocities. When using an impingement plate do not have large escape
velocities: larger shells are often needed to accommodate an impingement
plates satisfactorily.
With condensers, provision of a vapor belt is a useful way of reducing inlet
velocities and obtaining uniform velocity distribution at the inlet. However the
cost of installing a vapor belt is high.
Use sealing strips if accurately known fluid velocities are essential to promote
long life: sealing strips should not be too close to the baffle cut line. It should
be noted however that sealing strips can give rise to large local velocities.
Avoid making the end spans any longer than necessary.
If long spans at inlet and outlet are unavoidable for any reason, provide
additional support for the window tubes near the mid-point of the long span.
Partial baffles are widely used to correct problems in inlet and outlet zones:
their use is recommended when impingement plates are necessary (five rows
deep).
Avoid liquids being trapped at baffles and so causing high local velocities:
adequate but not excessive drain holes (notches) must be provided.
There is some evidence that certain tube layout patterns are more conducive
to the formation of standing acoustic waves than others. The rotated square
tube layout should be avoided on this account, if possible, when the shell side
fluid is gas or vapor.
Consider the use of solid bars instead of tubes in the first two tube rows if
problems are indicated during design or encountered during operation.
Avoid, where possible, design with tubes located near to Hogging Jets in
condensers.
Do not use the minimum number of baffles in kettle and horizontal
thermosiphon reboilers: this is false economy. Particular difficulties can rise in
H-shell horizontal thermosiphon reboilers: here a tube support plate should
always be placed at the mid point of the tubes.
Natural frequencies are lowered by the presence of compressive stresses in
the tubes. The effect will be to render the tubes more susceptible to both
fluid-elastic instability and vortex shedding resonance. Designs should
therefore be examined critically to see whether compressive stresses arise. If,
for any reason, some compressive stress is unavoidable, its effect on the
natural frequencies should be calculated. These natural frequencies should
then be used in any assessment of vibration characteristics.
Avoid sharp bends in inlet pipework: major swirl can cause excessive
velocities.

See also:
Avoiding Vibration during Manufacture
Avoiding Vibration during Operation
 Shell&Tube Vibration: Avoiding Vibration
during Manufacture
Ensure that anti-vibration bars are made from compatible material and so
avoid minimize wear/fretting problems: also ensure that they have adequate
interference and are adequately located.
Ensure that acoustic baffles are no thicker than necessary so as to avoid
layout difficulties: experience has shown that a baffle of only 0.6 mm (0.022
inch) thickness is adequate for frequencies of 250 Hz. However for mechanical
and corrosion reasons far thicker baffles are commonly used.
Tubes are sometimes distorted to ensure positive contact at the first baffle.
Ensure all baffles are inspected for oversized tube holes before assembly
starts. Burrs at baffle holes or vapor should be removed.
Check tie-bars for buckling.

See also
Avoiding Vibration during Operation
 Shell&Tube Vibration: Avoiding Vibration
during Operation
NEVER permit heat exchangers to be in circuit during pipe cleaning at initial
start up.
When plant operation is changed or up-rated, it will be necessary to have the
heat exchanger design re-examined.
Use solid bars inside worn or cracked tubes: blank off the tube end with a
plug or a welded insert.
Ensure that the flow in banks of parallel identical heat exchangers is
controlled to be as similar as possible: flow ratios of 2:1 are thought to have
been present in some cases where failure has occurred.
Consider the possibility of vapor collapse in condensing systems: liquid slugs
can do severe damage if they reach high velocity after the vapor collapse.
This could happen, for example, when a plant was shut down.

See also:
Avoiding Fluid-Elastic Instability
 AirCooled: Starts at Pass
Enter the lowest pass number that has the enhancement fitted.
 AirCooled: Stops at Pass
Enter the highest pass number that has the enhancement fitted.
 AirCooled: Heat Transfer Coefficient Factor
Enter the number by which the calculated tubeside heat transfer coefficient
(liquid, two phase, or vapor) should be multiplied.
Program calculated values should normally be used unchanged, unless you
have a very good reason for scaling them.
 AirCooled: Frictional Pressure Gradient Factor
Enter the number by which the calculated tube side frictional pressure
gradient (liquid, two phase, or vapor) should be multiplied. It is not possible
to scale the pressure drops of each phase separately.
Program calculated values should normally be used unchanged, unless you
have a very good reason for scaling them.
 AirCooled: Reynolds Number
Enter values of Reynolds Number for the first and second points which
correspond with input values of tube side heat transfer j factors and friction
factors.
The reference diameter is the tube inside diameter.
Note 1: A log-log interpolation is performed between two points.
Note 2: Extrapolation is not permitted.
 AirCooled: Heat Transfer j Factor
Enter values of the heat transfer j factor corresponding to the values of the
Reynolds Number for Points 1 and 2.
This is particularly useful for specifying the performance of tube inserts.
Note 1: A log-log interpolation is performed between two points.
Note 2: Extrapolation is not permitted.
 AirCooled: Frictional f Factor
Enter values of the friction factor corresponding to the values of the Reynolds
Number for Points 1 and 2.
This is particularly useful for specifying the performance of tube inserts.
Note 1: A log-log interpolation is performed between two points.
Note 2: Extrapolation is not permitted.
 AirCooled: Twisted Tape Thickness
Enter the thickness of the twisted tape insert.
Default value = 0.5 mm (0.02 in)
For further details, refer to HTFS handbook sheets SM27 and SM28.
 AirCooled: 180 Degree twist pitch
Enter the pitch of the twisted tape insert as it completes one 180-degree
twist.
Default value = 50 mm (2 in)
For further details refer to HTFS handbook sheets SM27 and SM28.