Overview of Heat Exchanger Design-R5

L&T Heavy Engineering
An Overview of Thermal Design of

Heat Exchangers
October 7, 2015 © 2015 Larsen & Toubro Limited : All rights reserved
Contents
• Introduction
• Objective of thermal design of Heat Exchangers
• Data Required for thermal design
• Step by step design methodology
• Thermal design & check rating
• Flow Induced Vibration
• Case Studies
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Introduction
• Shell and tube heat Exchanger is by far the most widely used type of heat
exchanger in oil refining, chemical, petrochemical and power industries.
• S&T accounted for 85% of new exchangers supplied to leading European
countries.
Why Heat Exchangers are Popular ??

1) Can handle all fluids over wide range of operating conditions.
2) Variety of components & complex constructional features.
3) Thermal, Mechanical reliability in service.
4) Can be built with varied MOCs.
5) Rugged and Safe Construction.
6) Competitive market.
TEMA Heat
Exchanger
Nomenclature
Design Philosophy
The creation of equipment to accomplish

desired thermal changes within minimum
operating & investment costs and with proper
attention to the mechanical integrity and
operational flexibility of the heat exchanger in
service.
Data to be furnished
• Flow rate
• Inlet/outlet temperature
• Heat Release Profile and
physical properties
• Operating pressure
• Allowable pressure drop
• Fouling resistance
• Geometrical constraints
Steps in Thermal Designing
• Allocation of fluids
• Selection of Front Head-Shell-Rear Head
• Material of construction
• Selection of - Tube OD; Pitch; Tube Layout and Tube Length,
• Selection of Baffle type & orientation
• Nozzle sizing
• Location of nozzles
• Stream Analysis
• Rating/Design of the Exchanger
• Vibration analysis
• Nozzle sizing
• Stream Analysis
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Allocation of fluid
 Safety:
• The hazardous fluids can be placed on shellside or tubeside except for-
P-type or W-type rear head of exchanger.
 Reliability:
• General rule is to allocate corrosive fluids to the tubeside.
• High temperature lethal fluids are kept on Shell side.
 Operating practice:
• It is preferred to allocate cooling water always to the tubeside.
 Ease of maintenance:
• Fluids causing heavy fouling should be placed on tubeside as cleaning is easy
on tubeside.
 Capital cost:
• Fluids which require exotic material should be placed on tubeside.
• High pressure fluid should be allocated to the tubeside.
• Fluid with high Volumetric flow rate to be allocated to shellside.
• Nozzle sizing
• Stream Analysis
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Front head type

● Order of priority in selection:
1. If tubeside fluid is hazardous,
consideration should be given to
“C or N Type” or bonnet welded to
the tubesheet.
2. If tubeside pressure is very high,
consideration should be given to
using a “D Type” or bonnet welded
to tubesheet.
3. “A Type” head is standard for most
oil companies.
4. “A Type” head for exchangers with
dirty fluids on tubeside.
5. “B Type” is the cheapest and
widely used.
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Shell type
 Order of priority in selection
1. E type shells are standard
2. G and H shells are normally
specified only for horizontal
thermosyphon reboilers.
3. J and X types if the allowable
pressure drop cannot be
accommodated in E-type design.
4. F type is used for pure counter-
current in 2 tube passes.
5. K type is for Kettle reboilers.
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Rear head type

 These fall into three general types
1. Fixed tube sheet (L, M, N)
2. U-tube
3. Floating head (P, S, T, W)
 Use fixed tubesheet if ΔT (Tube to shell metal temperature

difference) below 50oC, otherwise-
a) Use floating head designs to allow for differential thermal expansion.
b) Use bellows in shell to allow for expansion but these are are not
recommended for shell side pressure higher than 35 bar.
c) Use U tubes
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Rear head type

Order of priority in selection-
 P and W-type would be considered only for special cases. For normal
service following are used.
 Fixed tubesheet (L, M, N-type) provided that:
•There is no overstressing due to differential expansion.
•The shell side will not require mechanical cleaning.
 Fixed tubesheet with bellows provided that:
•The shell side pressure does not exceed 35 bar.
•The shell side will not require mechanical cleaning.
•Tube-to-shell metal temperature difference, ΔT > 50° C.
• Nozzle sizing
• Stream Analysis
• Selection of - Tube OD; Pitch; Tube Layout and Tube Length
• Nozzle sizing
• Stream Analysis
Selection of Tube Size
Tube OD
Straight Tube U tubes
Tube OD 15.875/19.05/25.4
Thickness Min. as per API 660 or licensor requirements
Tube Length 3660, 4880, 6096, 7315 max 7315 max
Tube Pitch 30, 60 – High turbulence required, No cleaning required

45, 90 – Mechanical cleaning is required, result in larger Shell ID
Selection Fouling, Pressure drop, Expansion, Geometrical Constraints
Selection of Tube Size…

Tube Layout
• Nozzle sizing
• Stream Analysis
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Selection of Baffles Type & Orientation

Baffle Type
Baffle Type Preferred for
 Single segmental • Typically Used
 Double segmental • Low Allowable Pressure
Drop
• Lower Potential for FIV
 Triple segmental • Lower Allowable Pressure
Drop
• Lower Potential for FIV
 No-tubes-in Window • Specifically To Mitigate FIV
segmental • Higher heat transfer
coefficient
 Rod baffle • Longitudinal Flow
• Low pressure drop
 Helical Baffle • Low pressure drop
• Shell side heat transfer
resistance is governing
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Selection of Baffles Type & Orientation. . .

Baffle Cut & Orientation
• Taken as % of shell ID
• Baffle cut vary in between 15-45 %, but
recommended value is between 20-25%.
Horizontal Cut Vertical Cut (Parallel)
(Perpendicular)
Single phase fluid Two phase fluid
services services
TEMA Type – E, J TEMA Type – F, G, H
• Selection of cut is an iterative process –

based on pressure drop, bypass streams,
heat transfer coefficient.
Selection of Baffles Type & Orientation. . .

Baffle Cut & Orientation
• Baffle cut specified with respect to shell inlet nozzle location.
Parallel Cut
• Nozzle sizing
• Stream Analysis
Nozzle Sizing
• Nozzle Sizing
• Nozzle ρ-V2 • ≤ 6500 kg/ms2 on Shell side and
• ≤ 15000 kg/ms2 on Tube side
• Shell entrance ρ-V2 • ≤ 5953 kg/ms2

• Nozzle pressure drop • @ (10% of total pressure drop)
What is ρ-V2 ?
TEMA GUIDELINE
API 660 GUIDELINE
Shell entrance area

• Area above the tube bundle available for flow distribution.
• Based on the area, ρ V2 is calculated.
• Should be less than Nozzle ρ V2.
• Nozzle sizing
• Stream Analysis
Nozzle Location
Nozzle Location
Fluid should follow the Natural Convection Flow Path
Heating Fluid Cooling Fluid

Bottom to Top Top to Bottom
Boiling Fluid Condensing Fluid
Impingement Protection
Impingement Protection -TEMA Requirements
Shell Side
• Non-abrasive, Single phase fluids: • If Rho-V2 ≥ 2232 kg/ms2
• All other liquids, including a liquid • If Rho-V2 ≥ 744 kg/ms2

at its boiling point
• Two Phase flow • Always Required
Tube Side
Use of an axial inlet nozzle.
Liquid Rho-V2 ≥ 8928 kg/ms2
Types of impingement Protection:

• Plate
o Circular
o Rectangular
• Rods
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Number of passes
Number of Passes depends on :
 Velocity requirements
 Available pressure drop
 Phase separation possibilities
 Possibility of welding pass partition
plates
• Nozzle sizing
• Stream Analysis
Clearances
Clearances as Per TEMA:
• Bundle To Shell ID
• Baffle OD to Shell ID
• Tube OD to Baffle Hole
Tube OD to Baffle Hole
Baffle OD to Shell ID
Bundle to Shell
Type of Exchanger diametric clearances
(mm)
• Fixed tubesheet exchanger 15-20
• U-tube heat exchanger 15-20
Bundle To Shell ID • Floating head exchanger (S Type) 45-60
• Pull through floating head exchanger (T Type) 140-200
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Shell Side Stream Analysis

Stream Analysis
• B Stream : Main Cross Flow ≥ 50 %
• A Stream : Baffle Hole Tube Leakage ≤ 20 %
• C Stream : Bundle Bypass Stream ≤ 20 %
• F Stream : Pass Partition lane ≤ 20 %
• E Stream : Shell-Baffle Leakage ≤ 20 %
Bypass sealing devices

Sealing Strips
Impingement
• Sealing strips rods
• Bypass seal rods
Seal rods
• Nozzle sizing
• Stream Analysis
Simulation, Rating & Design of Heat Exchanger

Simulation Rating Design
Flowrate   
•Inlet
Rating : Evaluation of the performance of a fully specified
temperature   
heat exchanger
Inlet Pressure   
(To evaluate performance of the exchanger in operation)
Allowable pressure drop  
• Design : Determination of construction parameters for 
an
Fouling
unknown heat exchanger starting  with given  process 
conditions.
Duty Output  
•Outlet
Simulation:
temperature Prediction of Output
the exchanger performance for the
 
available geometry.
Geometry   Output
Overdesign - Output -
Calculated Pressure drop Output Output Output
Design of Heat Exchanger
Selection of a Basic heat

Process Input Exchanger Type
Selection of a tentative set of

exchanger geometric/ design
parameter
Modification of the
Rating of Geometry
Design parameter
Design Evaluation :
• Overdesign
• Heat Duty
• FIV
• Δp
Mechanical Design, costing

etc
Thermal Design of Heat Exchanger

• Flow Rate 1. Heat transfer coefficient for
• Temperatures shell side, tube side,
• Pressure resistances.
• Exchanger Configuration 2. LMTD
• Fluid properties 3. Overall Heat transfer Coeff(U)
• Fouling Factors
• Allowable Pressure drop
Heat Transfer correlation

Pressure Drop Correlations
4. Q=U×ARequired×LMTD
Overdesign on surface area
Calculated Pressure Drops 5. Over design = ARequired/AProvided
Overall Heat Transfer Coefficient
Q = U.A.LMTD
Where Q = Heat Duty
U = Overall Heat Transfer Co-efficient
A = Effective heat transfer area (considering OD) of tubes
LMTD = Logarithmic Mean Temperature Difference.
LMTD = ∆T1 - ∆T0
ln ∆T1
∆T0
• Nozzle sizing
• Stream Analysis
Flow Induced Vibration in Heat Exchangers
• Shellside flow can cause vibration and noise problems in shell

and tube heat exchangers. These flow related phenomena are
called “Flow Induced Vibrations (FIV)”.
• FIV combined with Heat transfer and Pressure drop is the
primary factor controlling the design
• No. of reported serious vibration problems in Heat Exchangers
have increased dramatically over the years caused by
increased shellside flow rates.
Fluid-elastic Whirling
• Fluid-elastic Whirling is a phenomenon in which tube vibrates in an
orbital motion.
• It is produced by flow across tubes causing a combination of lift and
drag displacements of the tubes at their natural frequencies.
• If the energy fed to the tube by the flow exceeds that which can be
dissipated by damping, it can lead to “run away” condition for the
tube
Flow Induced Vibration of Multiple Cylinders_HIGH.mp4
Vortex Shedding
• Flow across a tube produces a series of vortices in the downstream wake
formed as the flow separates alternately from the opposite sides of the
tube.
• The alternative shedding of vertices produce alternating forces which
occur more frequently as the velocity of flow increases.
• When Vortex shedding frequency coincides with the natural frequency of
the tubes, resonance can occur.
Design Changes to avoid FIV
Inlet support Double-segmental baffles

baffles
Intermediate baffles
Windows
Tubes
with no tubes
No tubes in the window - with intermediate support baffles

Dimpled Tube Supports
Dimpled Tube Supports
Case: Design - FIV Failure

Equipment: Deisohexaniser Reboiler
Project: DTA Refinery, Jamnagar
Client: Reliance Industries Limited.
Location : Jamnagar, Gujrat, India
PROCESS DATA:
Fluid Allocation Shell Side Tubeside

Fluid Circulated Hydrocarbon MP Steam
Mass Flow rate 745120 36141
(kg/Hr)
Temp (in/out)Deg-C 146/147.26 201/199.48
Op. Press.(kg/cm2) 3.676 16
Heat Exch.(kcal/hr) 17160786
LMTD Deg-C 51.8
Case: Design - FIV Failure

Equipment: Deisohexaniser Reboiler
Project: DTA Refinery, Jamnagar
CASE : DESIGN – FIV Failure

Failure Root Cause
• Maximum unsupported span exceeds 80% TEMA limit.
• Flow induced vibration problem was present in the heat exchanger
Resolution:
• DTS strips used to reduce unsupported span & Increase the Natural Frequency of
tubes
Recommendation
• FIV analysis at design stage
CASE : DESIGN – FIV Failure

Failure Root Cause
• Maximum unsupported span exceeds 80% TEMA limit.
• Flow induced vibration problem was present in the heat exchanger
Resolution:
• DTS strips used to reduce unsupported span & Increase the Natural Frequency of
tubes
Recommendation
• FIV analysis at design stage
CASE : DESIGN – FIV Possibility

Equipment: Waste Heat Boiler
Project: Lukoil, Volgograd
Client: Tecnicas Reunidas
Location: Volgograd, Russia
PROCESS DATA:

Fluid Circulated STEAM/WATER PROCESS GAS
Mass Flow rate (kg/Hr)(Recirc. Ratio) 133251.3 (1:20) 222101
Temp (in/out)Deg-C 259.6/259.6 905/288
Op. Press.(kg/cm2) 47.53 35.33
Heat Exch.(Gcal/hr) 52.95
LMTD Deg-C 197.54

Equipment: Waste Heat Boiler
Project: Tecnicas Reunidas/Lukoil, Volgograd
Possibility of Vibration Conclusion / Recommendation

• Maximum unsupported span exceeds • Ring type Baffles supporting peripheral
80% TEMA limit. tubes
• Customer suggested additional
supports for the peripheral tubes
CASE : Operation
Equipment: Make Gas Boiler
Project: Sipchem
Client: Chiyoda Corp./Jacobs Engg.
Location:Al Jubail, Saudi Arabia
PROCESS DATA:

Fluid Circulated STEAM/WATER MAKE GAS
Mass Flow rate (kg/Hr)(Recirc. Ratio) 212970 (1:12) 199747
Temp (in/out)Deg-C 320/320 860/395
Op. Press.(kg/cm2) 112.4 19.5
Heat Exch.(KW) 73575
LMTD Deg-C 235.5
CASE : Operation
Equipment: Make Gas Boiler
Project: Sipchem
Failure Root Cause

o High Heat Flux causing vapour blanketing on tubes
o Operating at high load
o Increase in the tube & Tubesheet wall temperature
Conclusion / Recommendation
o Heat flux should be limited below critical heat flux
CASE : Operation
CASE : Optimization
Equipment: Screw Plug Exchangers
Project: Clean fuel project
Client: KNPC/Petrofac
Location: Kuwait.
PROCESS DATA:

Fluid Circulated HYDROCARBON/H2 HYDROCARBON/H2
Mass Flow rate (kg/Hr)(Recirc. Ratio) 318725 46487
Temp (in/out)Deg-C 381.8/346.7 244.7/368.2
Op. Press.(bar) 171.715 182.515
Heat Exch.(MW) 13.77
LMTD Deg-C 39.2
CASE : Optimization
Equipment: Screw Plug Exchangers
Project: Clean fuel project
o Vibration Possibilities as TEMA span exceeds

o Violation of API requirement of shell entrance ρ V2
Recommendation
o Alternate design with NTIW configuration.
Thank You

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L&T Heavy Engineering

An Overview of Thermal Design of

Why Heat Exchangers are Popular ??

The creation of equipment to accomplish

Front head type

Rear head type

 Use fixed tubesheet if ΔT (Tube to shell metal temperature

Rear head type

Tube Length 3660, 4880, 6096, 7315 max 7315 max

Tube Pitch 30, 60 – High turbulence required, No cleaning required

Selection Fouling, Pressure drop, Expansion, Geometrical Constraints

Selection of Tube Size…

Selection of Baffles Type & Orientation

Selection of Baffles Type & Orientation. . .

TEMA Type – E, J TEMA Type – F, G, H

• Selection of cut is an iterative process –

Selection of Baffles Type & Orientation. . .

• Baffle cut specified with respect to shell inlet nozzle location.

• Shell entrance ρ-V2 • ≤ 5953 kg/ms2

API 660 GUIDELINE

Shell entrance area

Heating Fluid Cooling Fluid

• All other liquids, including a liquid • If Rho-V2 ≥ 744 kg/ms2

Liquid Rho-V2 ≥ 8928 kg/ms2

Types of impingement Protection:

Shell Side Stream Analysis

Bypass sealing devices

• Bypass seal rods

Simulation, Rating & Design of Heat Exchanger

Design of Heat Exchanger

Selection of a Basic heat

Selection of a tentative set of

Mechanical Design, costing

Thermal Design of Heat Exchanger

Heat Transfer correlation

Overall Heat Transfer Coefficient

Flow Induced Vibration in Heat Exchangers

• Shellside flow can cause vibration and noise problems in shell

Flow Induced Vibration of Multiple Cylinders_HIGH.mp4

Design Changes to avoid FIV

Inlet support Double-segmental baffles

No tubes in the window - with intermediate support baffles

Dimpled Tube Supports

Dimpled Tube Supports

Case: Design - FIV Failure

Fluid Allocation Shell Side Tubeside

Case: Design - FIV Failure

CASE : DESIGN – FIV Failure

CASE : DESIGN – FIV Failure

CASE : DESIGN – FIV Possibility

Fluid Allocation Shell Side Tubeside

CASE : DESIGN – FIV Possibility

CASE : DESIGN – FIV Possibility

Possibility of Vibration Conclusion / Recommendation

Fluid Allocation Shell Side Tubeside

Failure Root Cause

Fluid Allocation Shell Side Tubeside

o Vibration Possibilities as TEMA span exceeds

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