Design and Estimation of Shell and Tube Heat Exchanger
Srishti Shrivastava
Heat Exchanger and Types
• Used to transfer heat from one medium to another.
• Media may be a gas, liquid, or a combination of both.
• Heat is transferred between the Hot and Cold fluid through a solid wall
which separates the fluids.
• Required to be kept within a safe operating conditions.
• Also used to capture and transfer steam or heat exhaust for better use
elsewhere, thereby increasing efficiency and adding value to business.
Types of Heat Exchangers
Double Pipe Exchanger Shell and Plate Exchanger Plate and Frame Exchanger
Air Cooled or Fin-Fan Exchanger Shell and Tube Exchanger
Shell and Tube Heat Exchangers (STHE)
• They are one of the most popular types due
to flexibility to allow for a wide range of
pressures and temperatures.
• In the petrochemical industry STHEs tend to
follow standards from TEMA
• STHEs are of 3 major types:
o Fixed tubesheet exchangers (Tubesheet
Welded to Shell)
o U-tube exchangers (Removable Bundle)
o Floating header exchangers (Removable
Bundle) Typical Shell and Tube Heat Exchanger
Typical Designing Sequence
Define process requirements
Select suitable HE type
(Inlet-outlet T&P, duty etc. )
Mathematical modeling to Define parameters : Length,
fine tune parameters and tube passes, material, baffle
accept them spacing etc.
Create specification sheet and details as per the model
Information required for Designing STHE Exchanger:
1. Flow rates of both streams.
2. Inlet and outlet temperatures of both streams.
3. Operating pressure of both streams.
4. Allowable pressure drop for both streams.
5. Fouling resistance for both streams.
6. Physical properties of both streams.
7. Heat duty consistent for both the shellside and the tubeside.
8. Selection of heat exchanger type
9. Line/ Connection sizes. (To match nozzle sizes with line sizes)
Thermal Rating/Design
With all available data an approximate size of the exchanger is selected (Based on space
availability in the plant, weight constraints and P&ID)
Fluid is allocated to either tube or shell side
High-pressure the stream should be located on the tube side.
The corrosive fluid is placed on the tube side.
Stream exhibiting the highest fouling should be located on the tube side.
More viscous fluid should be located on the shell side.
Lower flow rate stream should be placed on the shell side.
Stream with a lower heat transfer coefficient goes on the shell side.
Toxic fluid should be placed on the tube side.
Material is decided based on thermal conductivity, resistance to corrosion etc
Basic Formulae for Calculations
Where : q = heat flux, Btu/hr/ft2 or W/m
Q = Total Heat Transfer, Btu/hr or W
There are five layers through which the heat must flow: A = Heat Transfer Area, ft2
1. The inside boundary layer h = Heat Transfer Coefficient, Btu/hr-ft2-oF
2. The inside fouling layer T = Temperature, oF
3. The tube wall
4. The outside fouling layer
5. The outside boundary layer
Typical datasheet
calculated in HTRI
Mechanical Design of STHE
Thickness of material for each
component is calculated based on
max design temperature, MDMT and
pressure. TEMA table minimum shell thickness
Additional components like U-bend
supports, Support baffles or
expansion joints may also be required
Tube to tubesheet Joints are
recomeneded
TEMA table for minimum baffle thickness
Codes and Standards
Code rules and standards are to achieve minimum requirements for safe construction by
defining materials, design, fabrication, and inspection requirements
Following are some mechanical design standards and pressure design codes
1. TEMA standards (Tubular Exchanger Manufacturer Association., 1998)
2. API (American Petroleum Institute)
3. ASME (American Society of Mechanical Engineers)
4. HEI standards (Heat Exchanger Institute, 1980)
Non-Destructive Testing and Examination
• X-RAY – To check Quality of Welds
• Ect/ iris – To check Quality of tubes
• Hydrotest/ Air test – To check for leaks from gasket surfaces or welds
• UTT – To check thickness of material
• P.T. /WFMT – To check
Reference
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Reference
Shell-and-Tube Heat Exchanger Design, R. Shankar Subramanian, Department of Chemical and
Biomolecular Engineering, Clarkson University
Shell and Tube Heat Exchangers Basic Calculations, Jurandir Primo, PE
Thermal Design of Shell and tube heat Exchanger, Mechanical Engineering Department, King Abdulaziz
University
HEAT EXCHANGERS, Prepared by Bob Heaslip KESCO For Queens University, CHEE 470 – Fall 2008
Effectively Design Shell-and-Tube, Copyright 1997 American Institute of Chemical Engineers.
Heat Exchangers Specifying, “Understand what heat exchanger design specialists need to know — and
remember, you know your process best” Asif Raza
