Step 1: Specification Material Crude oil Kerosene T in 200 40 T mean Cp (145C) Duty 145 2.47 754.

7222222 T in C 40 200 T out 90 67 C kJ/KgC kW T out C 67 90

34o API 42o API

Shell Tube

754722.222

Step 2: Physical Properties Kerosene Temperature Specific Heat Thermal Conductivity Density Viscosity Inlet 200 2.72 0.13 690 0.22 Mean 145 2.47 0.132 730 0.43 Outlet 90 2.26 T 770 0.8

Step 3: Overall Coefficient For an exchanger for this type, the overall coefficient will be in the range of 300-500 w/mC See figure 12.1 and table 12.1; so start with 300

Step 4: Exchanger Type Dimension Tlm = (Thi - Tco) - (Tho - Tci) ln [(Thi - Tco)/(Tho - Tci)] 81.89229794

Tlm

Thi - Tho Tco - Tci 4.074074074

Tco - Tci

Thi - Tci = 0.16875

From figure 12.19, Ft Tm

= =

0.92 75.34091411

Step 5: Heat Transfer Area

Uo

q AoTm q UoTm 33.39142841

Ao

Step 6: Layout and Tube Size Using a split ring floating head exchanger for efficiency and ease of cleaning Outer Diameter Internal Diameter Triangular Long Tubes Pitch/ Diameter 19.05 14.83 23.81 5 1.25 mm mm mm m 0.01905 0.01483 0.02381 5000

Step 7: Number of Tubes

Area of one tube (neglecting thickness of tube sheet) = Number of tubes So, 2 passes, tube per pass = = 0.2992367 m 111.5886801 Say 55.5 Say

Check the tube-side velocity at this stage to see if it look reasonable Tube cross sectional area = 0.000172732 m

Area per pass Volumetric Flow Rate

= =

0.009672978 m Flow of Crude x 3600

= Tube Side Velocity, Ut =

0.016818708 m/s 1.738731069 m/s

Hence, the velocity is satisfactory, between 1 and 2 m/s.

Step 8: Bundle and Shell Diameter From Table 12.4, for tube passes, K1 n1 Bundle Diameter, Db Pt do Db = = = = = = Outer Diameter x 1.25do 0.019048 m 302.150182 mm 0.249 2.207 (Nt/K1)^(1/n1)

For a spliting floating head exchanger the typical shell clearance from figure 12.10 is 53 mm, so the shell inside dia Ds = 355.150182 mm

Step 9: Tube Side Heat Transfer Coefficient Re = xUtxDi 6049.309164 Cpx Thermal Conductivity 53.5880597 337.1544167 0.0038

= Pr =

= L/D From figure 12.23, jh = =

Nu Nu hi

= = = =

jh x Re x Pr^0.33 85.52278363 Nu x (Thermal Conductivity/ Internal Diameter) 772.7614974

Step 10: Shell-side heat transfer coefficient As a first trial take the baffle spacing = = = Ds/5 71.03003641 5041.014512

As Equilateral triangular pitch de =

1.1 (Pt - 0.917do) do 13.51957786 mm = = = = 0.003805175 0.754845276 17325.63009 8.046212121

= Volumetric flow rate on shell side Shell side velocity Re Pr

Use segmental baffles with a 25% cut. This should give a reasonable heat transfer coefficient without too large a p From figure 12.29, jh = 0.0048 hs = 1615.795011 W/mC

Step 11: Overall coefficient Kw 1/hi 1/hid ln do/di = = = = 55 0.00129406 0.00035 0.250414945

1/ho 1/hod 1/Uo Uo

= = = =

0.00061889 0.0002 0.002930853 341.1975878

Step 12: Pressure Drop Re Ut From figure 12.24, jf Pt = = = = = 6049.309164 1.738731069 0.0053 41930.37008 N/m 0.42 bar

Pressure in (bar) 6.5 5 Hours 1

Permissible Pressure drop (bar) 1 1 Second 3600

Fouling Factor (W/m2C) 0.0003 0.0002

C kJ/kgC W/mC kg/m mNsm-

Crude oil Temperature Specific Heat Thermal Conductivity Density Viscosity

Outlet 67 2.07 0.134 812 2.86

w/mC

Tco) - (Tho - Tci) hi - Tco)/(Tho - Tci)]

m m m mm

111 tubes 56

1 density

19.05 mm 0.302 m

0 is 53 mm, so the shell inside diameter

Internal Diameter)

say mm

71 0.005041 m

0.01352 m

m/s

coefficient without too large a pressure drop.

Mass Flowrate (kg/h) 50000 10000

Mean 53.5 2.04 0.134 825.8 3.52

Inlet 40 2.01 0.135 840 4.3

C kJ/kgC W/mC kg/m mNsm-

cost estimation guthrie method

K1 K2 K3 A

4.8306 -0.8509 0.3187 33.4

log10Cp= Cp=

4.274003 2033986

Fm Fp b1 B2 Cp

1 1 1.63 1.66 2033986

Cbm=

6691816

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Customer Address Plant Location Service of Unit Size Surf/ Unit (Gross/Eff) Fluid Allocation Fluid Name Fluid Quantity, Total Vapor (In/Out) Liquid Steam Water Noncondesable Temperature (In/Out) Density Viscosity/ Liquid Molecular Mass, Vapor Molecular Mass, Noncondensable Specific Heat Capacity Thermal Conductivity Latent Heat Inlet Pressure Velocity Pressure Drop, Allow./Calc Fouling Resistance (Min.)/Calc Heat Exchanged Transfer Rate, Service

Oil to Oil Exchanger

PERFORMANCE OF ONE UNIT

kg/h

She Ker 10

C kg/m mPa.s

In 200 690 0.22

kJ/(kgC) J/(s.m.C/m) kJ/kg @ C kPa m/s kPa mC/W

2.72 0.13

1 0.0

CONSTRUCTION OF ONE SHELL Shell Side Design/ Test Pressure kPa (ga) Design Temperature No. Passes per Shell Corrosion Allowance Connection Size Rating Tube No. Tube Type Shell Steel Channel or Bonnet Tubesheet-Stationary C mm In Out Intermediate 2 3

150#

ID

45 46 47 48 49 50 51 52 53 54 55 56

Floating Head Cover Baffles: Cross Baffles: Long Support: Tube Bypass Seal Arrangement Expansion Joint: Carbon Steel v- Inlet Nozzle Gasket-Shell Side Floating Head Code Requirement Weight/ Shell Remark

Type: Segmented

Oil Exchanger

Reference No. Proposal No. Date: Item No. Connected In

Rev: E-4 Parallel

E OF ONE UNIT Shell Side Kerosene 10 000 Tube Side Crude Oil 50 000

In 200 690 0.22

Out 90 770 0.8

In 40 840 4.3

Out 67 812 2.86

2.72 0.13 500 100 0.0002

2.26 0.135

2.01 0.135 650 100 0.0003

2.07 0.134

N OF ONE SHELL Shell Side

Sketch (Bundle/ Nozzle Orientation) Tube Side

2 3

2 3

150# Material: Carbon Steel ID OD Shell Cover Channel Cover Tubesheet: Floating

Type: Segmented

%Cut (Diameter/ Area): 25%

Impingement Protection Spacing: 75 mm

Inlet

Type: Flanged

Rev: E-4 Series

e Side de Oil 000

Out 67 812 2.86

2.07 0.134

50

00 003

Nozzle Orientation)

arbon Steel

Inlet

MECHANICAL DESIGN

specification shell tubes length 355.15 14.83 19.05 5000 mm mm id mm od mm 5 bar 6.5 bar

kerosene in the shell, operating pressure crude in the tubes, operating pressure

material of construction, semi-killed or silicon killed crbon steel a) Design Pressure: takes 10% greater than operating pressure shell = tubes= 4.4 = 440000 N/m2 6.05 =650000 N/m2

design temperature: 200 oC take this design temperature both shell and tubes. The tubes could reach the kerosene temperature if there was no flow of crude oil b) corrosion allowance kerosene= crude oil= 2 mm 4 mm

c) end covers used torispherical, header-cover flat plate d) stressing from table 13.2, design stress is shell: e=

105 N/mm2 at 200oC 0.0008 m = 2.8 mm 5 mm 1.1 mm 0.8 mm

add corrosion allowance=

thiss is less than the minimum recommended thickness so round up to header: e= 0.0011 m = 5.1 mm

add corrosion allowance = shell end cover, torispherical, take Rc = Rk/Rc = Cs =

0.3 0.1 2.37 take joint factor as 1 formed head

0.00148 m =

= 3.5 mm

1.5 mm

add corrosion allowance

floating head torispherical: from figure 12.10 bundle to shell clearance, take as split ring Db take Rc = Rk/Rc = Cs= e= = 0.3 0.1 2.37 0.00206 m 53.15 mm = 53

= 6.1 mm

2.1 mm

add corrosion allowances = flat plate (header cover) type e, Cp= Di= De= e= 0.55 355 mm 0.4 m 0.167 m

0.35 m

= 20.7 mm

16.7 mm

add corrosion allowance =

all thickness will be rounded to the nearest standard size e) Tube rating tube id= 14.83 mm tube od= 19.05 mm design stress = 105000000 N/m2 design pressure = 6.05 N/m2 thickness required , e = actual wall thickness = 0.0000053 m 2.11 mm = 0.005

f) tube sheet thickness should not be less than tube diameter take thickness as 20 mm shell od= 365.15 mm = 440000 say N/m2 200 oC 370 mm

design pressure= design temperature

refer to table 13.5, 6 bar rating will be satisfactory

floating head od design pressure design temperature

350 mm 6.05 N/m2 200 oC

based on the table 13.5 use 10 bar rated flanged h) supports use saddle supports diameter length 0.4 m 10 m 0.063 m3 0.0004 0.0005 0.0026 0.0026 ignoring the holes 0.115 77

shell and header volume of steel volume of shell head, take as flat volume of floating head, take as flat volume of flat plate end cover volume of tube-sheet volume of tube number of baffles taking baffles as 3 mm thick and ignore the baffle cut volume = total volume of steel shell shell head floating head end cover tube sheet tubes baffles total taking density of steel as mass of HE= weight HE= 1646.58 kg 16152.9498 N 0.063 0.0004 0.0005 0.0026 0.0026 0.115 0.027 0.2111 m3

0.027

7800 kg/m3

mass of water, ignore volum of tube weight= 12331.17 N maximum load on supports=

1257 kg 28484.12 N 29 kN