This help file will explain in details all software features and any common errors that the software may generate. S&THex is a software tool that is made to demonstrate the chemical design and rating calculations of Shell & Tube Heat Exchangers. The software unlike other tools, ensures that the calculations are performed step by step to help in understanding the calculations.
5 Main Features Software Features Step by step design and rating calculations Support S.I Units and English (U.S) Units of measurement Rating and Design Modes Save/Load results. Results: Export Results to Shell & Tube Engineering Data sheet. You can print the data sheet or export it to pdf format or Microsoft Excel for editing Export Results summary to Microsoft Excel, Print Results summary. Calculations: Duty, Shell/Tube velocities, Unknown shell or tube side temperatures, also calculate unknown exit temperatures in rating mode Number of Baffles and Baffle spacing, Scale resistance (dirt factor) Overall heat transfer coefficient for both Clean and Fouled conditions Select from different correlations to calculate shell or tube heat transfer coefficient Shell/Tube side Reynolds & Nusselt numbers Pressure Drops. Recommended minimum shell thickness, minimum recommended number & diameter of rods. Calculate Shell/Nozzle/Channel/Head/Tube sheet Thickness.. Number of transfer units, Effectiveness, Thermal capacity ratio Pumping power / Inlet and Exit Nozzles pressure losses / Scale resistance Calculators Ability to import properties to Shell/Tube sides form Microsoft Excel very useful if you want to import your own physical properties Included Databases: Estimate the Physical properties of pure components for more than 1450 components; the database has the ability to estimate Thermal Conductivity, Density, Heat Capacity and Viscosity. The database also included critical properties, boiling and melting points and come as a standalone interface but easily integrated with the software. Estimate mixture properties. (ALL ESTIMATION METHODS CURRENTLY SUPPORT LIQUIDS ONLY) Ability to add your own properties in the additional user databases. Fixed tube sheet counts and standard tube sizes tables Fouling factors and Overall heat transfer coefficients included.
6 Version History Product minor revisions have been omitted from version history S&THex v1.6 May 2010 Physical properties database separate interface Export Physical properties to Ms Excel or XML file. Import Physical properties from XML file. Export Summary to Shell & Tube Engineering Data sheet to Ms Excel or pdf format Fouling Factors Improved user interface Fixed few programming bugs
S&THex v1.5 July 2007 Added Fixed Tube sheet tube counts Added general Tube Sizes Added Rating mode Added Overall heat transfer coefficient calculations for clean and fouled conditions Added Effectiveness, Number of transfer units and Thermal capacity ratio calculation Added Pumping power calculation Added the ability to enter Nusselt number in the correlations section Added Gnielinski correlation to tube side Improved user interface Fixed few programming bugs
S&THex v1.4 July 2005 Added Software property estimation database (liquids property estimation only) Added Overall Heat Transfer Coefficients Table Added new saving function Ability to import and export to Microsoft Excel Improved user interface Estimation of Jh (heat transfer factor) - in correlations section Added Shell/Nozzle/Channel/Head/Tube sheet Thickness Calculation Fixed few programming bugs
S&THex v1.3 May 2004 Added Databases (empty user databases) Improved saving functionality Added print screen functions Fixed some common programming bugs
S&THex v1.2 Feb 2004 Added English (U.S. Units) Added Shell diameter calculation Added Scale resistance calculation/calculator
8 License Agreement Use of SHELL & TUBE HEAT EXCHANGER DESIGN [S&THex] (This SOFTWARE) is contingent on your agreement to the following terms: 1. GRANT OF LICENSE The AUTHOR of this SOFTWARE (Khaled Aljundi) and WeBBusterZ Engineering Software (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk), grants you a limited, non- exclusive license to use the SOFTWARE if you have purchased a copy or obtained the demo version. 2. DISCLAIMER: While reasonable care has been exercised in the collection of data and testing of this software, WeBBusterZ Engineering Software (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) and Khaled Aljundi (the AUTHOR of this software) disclaims any warranty, expressed or implied, as to the accuracy or reliability of the data or calculations contained therein. The physical properties obtained from this software yield approximate results, which will not always be suitable for every application. The software is designed for use by trained professional personnel and is not a substitute for sound professional judgment. It is the sole responsibility of the user to validate the data presented by this software and to determine whether the results are accurate and suitable for any specific purpose. No guarantee of accuracy or fitness for any purpose is expressed or implied. WeBBusterZ strongly recommends that the data be checked against other sources and/or methods before use and application. THE SOFTWARE IS PROVIDED AS IS WITHOUT WARRANTY OF ANY KIND. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR FURTHER DISCLAIMS ALL WARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON INFRINGEMENT. THE ENTIRE RISK ARISING OUT OF THE USE OR PERFORMANCE OF THE PRODUCT AND DOCUMENTATION REMAINS WITH RECIPIENT. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) OR THE AUTHOR BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, DIRECT, INDIRECT, SPECIAL, PUNITIVE, OR OTHER DAMAGES WHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR OTHER PECUNIARY LOSS) ARISING OUT OF THIS AGREEMENT OR THE USE OF OR INABILITY TO USE THE PRODUCT, EVEN IF (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES THE SOFTWARE IS PROVIDED AS IS WITHOUT WARRANTY OF ANY KIND. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR FURTHER DISCLAIMS ALL WARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON INFRINGEMENT. THE ENTIRE RISK ARISING OUT OF THE USE OR PERFORMANCE OF THE PRODUCT AND DOCUMENTATION REMAINS WITH RECIPIENT. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) OR THE AUTHOR BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, DIRECT, INDIRECT, SPECIAL, PUNITIVE, OR OTHER DAMAGES WHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS, BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR OTHER PECUNIARY LOSS) ARISING OUT OF THIS AGREEMENT OR THE USE OF OR INABILITY TO USE THE PRODUCT, EVEN IF (WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES
9 LICENSE: 3. SCOPE OF GRANT You may not reverse engineer, decompile or disassemble the SOFTWARE. WeBBusterZ and the AUTHOR shall retain title and all ownership rights to the SOFTWARE. 4. COPYRIGHT This SOFTWARE is protected by copyright laws and international copyright treaties, as well as other intellectual property laws and treaties. 5. MAINTENANCE WeBBusterZ and the AUTHOR are not obligated to provide maintenance or updates for the SOFTWARE. However, any maintenance or updates provided by WeBBusterZ and the AUTHOR shall be covered by this Agreement.
6. DISTRIBUTION
The Demo version of this SOFTWARE may be freely distributed provided that it is not modified and the original archive remains intact with all accompanying files, and provided that no fee is charged. Should a fee be charged or any of the distribution package need to be modified you must contact WEBBUSTERZ for explicit written permission. YOU MUST AGREE TO AND ACCEPT THESE TERMS IF YOU WISH TO USE THIS SOFTWARE
S&THex needs the following computer configuration to run:
Microsoft Windows operating system. 64MB RAM; 30MB free disk space; .Net Framework Tested Windows XP, Windows Vista & Windows 7. Acknowledgements
1. Standards of Tubular Exchanger Manufacturers Association, 6th Edition, TEMA Incorporated, Tarry town, Newyork, 1978 2. Sinnott, R.K., Coulson and Richardson's Chemical Engineering Design, Vol. 6 , Third edition, Butterworth-Heinemann 3. D. Q. Kern, Process Heat Transfer, McGraw-Hill, International Edition, 19504
Software Support
The support provided with this software is limited to NON Technical software issues. Please only contact us if you would like to report a software bug or problem. It is highly recommended that you test the demo version of this software before purchasing the full version.
11 Main Screen This will guide you through how to use the software, and how to avoid errors. S&THex is easy to use as long as you follow the instructions provided in this document: All calculations performed and screen captured are for demonstration purpose only and shouldn't be used as a reference. Many screens have been modified due to upgrades to newer version.
The software currently supports two units of measurement; S.I units and English (U.S) units. The software will use S.I units as default units. Before proceeding to do any analysis you must set the units of measurement. You have now different options to proceed. 1. You can load components from your user database.
12 2. You can load components from the software database 3. You can enter components to the software manually To load components from your user database, point to Database located at the top menu then select User. Your components are located under Components. To load components from the software database (contains 1495 components) click on the button labelled Estimation or simple point your cursor to Database and select Software. If you are entering the data manually, click on the button labelled Start
Design Mode Tool bar
From the left
1. New - This button will clear all text boxes for a new project. 2. Open- Load your saved project 3. Save - save your project 4. Back to main - The arrow will show the software main screen 5. Import an XML format file or a physical properties file 6. Import from Microsoft Excel 7. Help - This will access this help file. 8. Steps Navigation - Will show the window below.
All buttons are numbered and must be clicked in order to avoid errors.
1. Enter Shell/Tube side components 2. Select physical state 3. Temperatures, units - 'C, 'K if using SI units in this case. 4. Only one check box from either the Shell side or Tube side can be checked - this will allow for the Temperature prediction! - You can only ask the software to estimate only one temperature on both shell/tube sides. 5. Enter Flow rate - in kg/hr or m3/hr 6. Only one check box from either the Shell side or Tube side can be checked if you want to calculate an unknown flow rate. 7. Click the "Done" button.
1. Enter ALL values 2. You can check the checkboxes to calculate Prandtl Number. 3. If you have e.g. Steam then you must check the checkbox to enter the Specific Enthalpy
1. Click the "Calculate" button to calculate the duty 2. Enter assumed Uo value - this can also be obtained from Uo database by clicking "Open Database" 3. This will show as below - every entry you select will be automatically aligned to the opposite one in the database.
1. Enter the Shell Diameter - Values can be found from literature. However the Shell Diameter (Ds) and the Bundle Diameter (Db) can be estimated if the check box is checked the screen below would appear. You can adjust the clearance value by checking the "adjust clearance check box" then enter the clearance value and click the "adjust button", click the "Back button" to send the Ds value to the main screen. 2. Click "Done" button 3. If you click on "Standard pipe sizes" the screen below will appear, you can also find the sizes you need if you are using fixed tube sheet heat exchanger The tube counts for this can be found if you go to the main screen then click on "Tube counts"
1. Select Flow profile then click "Calculate" button 2. Select to either enter or estimate the true temperature correction factor then click "Calculate" button Step 6
1. Calculate the Heat Transfer Area 2. Also in some cases if any of the checkboxes in step1 was checked for estimating the Flow rate, then another "Calculate" button will appear for this purpose as shown below
1. All you need to do here is to click on the calculate button. 2. A check box to adjust the Number of Tubes will appear. 3. Adjust the Number of Tubes and click on the Calculate button again to re-calculate the
20 rest of the information. 4. When you click the Calculate button the screen below will also popup - Click on calculate to calculate the shell diameter (you can choose to adjust the clearance value by checking the check box and entering the new value then click on Adjust button
5. If the Checkbox for estimating the initial Design Overall Coefficient (Ud), the screen below will appear - Click the "Calculate" button to estimate. Note: The Ud estimation must be completed in order to enable the estimation of the dirt factor in later step.
1. Click the "Calculate" buttons in order 2. When Correlation Screen appears select the correlation. o First decide if you are ignoring the viscosity at wall or no - if it's ignored then check the checkbox provided. o For this case - Check the checkbox to calculate the Jh (heat transfer factor) - You can also select to enter the Nusselt number if you prefer o Click "Done" to go back to Step 8 Screen and calculate the Heat transfer coefficient
1. Select the Baffle cut and Type then click on the Done button to calculate the Cut. 2. Baffle diameter can be estimated after select (Pipe or Plate Shells). 3. You can edit the Baffle diameter value by checking the check box to edit the clearance, enter the value then click the "Calculate button" to calculate the Baffle diameter.
1. Jf is a dimensionless friction factor (the same as the friction factor for pipes) and can be obtained from literature (e.g. Reynolds number vs. Jf Charts). 2. Enter Jf and click the Calculate button. Note: Shell & Tube sides Nozzles pressure drop can be estimated by checking the check boxes provided. The screens below would appear. 3. Clicking on the other data button; will enable you to calculate (tube holes in baffles diameter, shell thickness, number of tie rods & diameter and baffle plate thickness). The estimations only are in fact recommendations based on TEMA Standards, so please check with the manufacturers for accuracy. The screen for "other data" can be seen below
Pumping Power can also be calculated for fluids only
Step 13
This Part of the software will only do some basic mechanical calculations After filling in all the data required the results button must be clicked to see the results.
Results screens Click the calculate button to show all answers Because the screen below only makes recommendations, if your Ds value is < 6 in the software won't be able to generate the results.
1. Note that every time you make a change to any entry in the problem specification you need to re-click the show button and scroll down to the new set of results 2. The summary also can be seen with only basic Graphical illustration, other CAD or drawing packages should be used for more accurate illustrations.
34 Temperature Prediction 1. Your first Specific heat capacity value is filled in by the software 2. Click the Calculate button to calculate the first trial 3. Use the average temperature generated for the second trial to obtain the Specific Heat Capacity for the second trial. 4. Click the "Calculate" button to calculate the Temperature. 5. Follow steps 3 and 4 except that you will use the average temperature generated for the third trial to obtain the Specific Heat Capacity value. 6. when you decide to stop, check the checkbox opposite to the trial number, then click the "Done" button to continue.
Select flow arrangement You can choose to calculate the area or duty however since this is rating of existing heat exchanger it's always better to have all such information available at hand, this will help in producing better results Thermal conductivity value for materials of constructions are available in literature
Enter exchanger layout and type Enter Tube details then click "1- Done" button - this will calculate the inside diameter Clicking on the "Standard pipe sizes" to show the pipe sizes database Enter Shell diameter
This is the tube side rating calculation screen - You must click the buttons in order Before clicking on "3- Calculate" button the check box must be checked to use a correlation to calculate Nusselt number
This is the shell side rating calculation screen Before clicking on "4- Calculate" button the check box must be checked to use a correlation to calculate nusselt number
Step 8
The results screen below is revealed after clicking of the Calculate button present in step 7
Summary screen - Click the "Show" button to show thee summary of results If you make changes to the results you will need to click on the "Show" button again and scroll down to the new set of results
The software can also generate an engineering data sheet that includes a summary of Rating / Design. On the summary screen the button below will allow you to export to a data sheet
When you click the button you will be presented with the screen below where you can type in any extra information before you generate the data sheet
The datasheet can be generated and exported directly to Ms Excel or can be generated and previewed as a report before exporting to Ms Excel
The data sheet should look as shown in the screen below. You have the ability to save the data sheet as a pdf file or export it to Ms Excel for editing. You can also print the data sheet, all options are explored below
The software offers a collection of databases for your own convenience, the screen below can be accessed via the main screen buy clicking on the button or
Please note: all estimation techniques will sometimes result in error factor. Professional judgment should be exercised with reference to all estimation made. We recommend checking properties against a literature source if in doubt. For Mixture Estimation - The following limitations apply: o Mixture Viscosity is only valid for Organic liquids only, o Mixture Thermal Conductivity only valid for non polar liquids only
All data are stored in sthex.mdb file and this can file can also be accessed from Microsoft Access. if you prefer. Components
The database function is to help in saving you time through projects. All you need to do is enter the component and its physical properties. When you are done, add the component. As you progress through adding the components you can load any component to any side (i.e. Hot or Cold side) by clicking the appropriate button. Before loading any component always make sure that you have selected the correct units of measurements from the software's main screen. This is simply to avoid conflicts between units of measurements.
Edit, Delete Refresh, Find, Filter, Sort ....etc. All above mentioned are there for your convenience and they can be used as you add more items to the software.
This database is extra, the software now have values Uo and they can be accessed from the main screen. The database should be used the same way as the components database, all buttons have the same functions.
Tube Counts can be accessed through the main screen, The counts below are valid for FIXED TUBE SHEET EXCHANGERS The database can be navigated by clicking on the "Next or Prev" buttons If you want a copy to print out, you can click on the PDF image button to open up the pdf file in Adobe viewer The find button can be used to search the database, this can be performed by searching by field Data Grid button will adjust the columns based on the longest field You can scroll to view records Horizontally as well as Vertically
Import The import feature is give you more flexibility. There is two ways that you can import data to the software. When you click on the import button present on the main screen
The screen below will popup
Ms Excel
The First method is to import from Ms Excel. You must have Microsoft Excel installed on your computer before you use this feature.
The Import wizard will allow you to import ANY values from ANY Excel Spreadsheet to the software
1. Click "Browse" to select the spreadsheet. 2. Ensure that the Sheet name is correct. 3. Specify the Cell references - only enter references as A1 or B14 ...etc. in the cell number textbox 4. Select the mode (rating mode / design mode) 5. Leave blank the cell that you don't want to use. 6. Click on the "Import" button to continue, the software will open the spreadsheet and import the values you specified then the speadsheet will be closed, you can also do this while the spreadsheet is open or running. 7. The software will also allow you to save the Sheet Cell numbers for future reference. To save: 1. Click on "Browse to Save" 2. Enter the name you want to save the Cell numbers under 3. Click on Save button to go back to the import screen 4. Click on the "Save" button provided to save all your values Important: You must make sure that you are importing value with the correct measurement units because the software will not convert your units 8. To Load your saved file: 1. Click "Browse to Open" button 2. select the saved document from the location you saved it under 3. Click "open" to go back to the import main screen 4. Click the "open" button provided to load your file.
The second method is to import from an XML file. This file is associated with the Physical properties database. Once you followed the instructions in physical properties user guide and generate an XML file you will need to import it using the tool below.
The first step is to browse to the XML file, you will need to click on the "Browse" button then find the XML file, the browse will usually start from the software default installation directory, so if you saved your properties file in the same directory you it should look similar to the one below.
When you open the file all the properties you generated will appear as below
Select the component and the units of measurements then assign the components to Shell/Tube/Hot/Cold side.
Then go to the main screen and continue to Step 1. All the properties should be loaded in Step 2.
Export
MS Excel This function will only work if you have Microsoft Excel installed on your PC!
The Export wizard can only export your summary of results obtained from the summary screen not the graphical summary. 1. Click on "Show" button to see the summary first. 2. Click on "Export" button to export your results.
For Exporting to Engineering data sheet please click here
Save/Load Project
Save Function 1
This will only save your values not your results.
Saving files 1. Enter the Project Name 2. Enter the location of the project including your file name This can be like: C:\Program Files\webbusterz\project1.txt Where project1.txt is the name of your project file. 3. Click "Save" button
Loading Files
1. Click "Open" to select the file (e.g. project1.txt) 2. Click "Open" button again to load your file
Save Function 2 Will save your results and values. Saving files 1. Click "Browse to save" button - and type in the name of your project 2. Click "save" to go back to saving screen 3. Click "Save" button on saving screen to save. Loading files 1. Click "Browse to open" button - this button will be enabled when you select "open" from the file menu on the main screen. 2. Select your file e.g. project1.dat 3. Click "open" to go back. 4. Click "Open" button to load your project.
This is the best way to gain some practice before running the software: You can also view the online demo video.
To load a test file do the following: 1. In the main screen set the measurement units first 2. Select "Open" from the main screen file menu, you can choose from opening a rating file or design file 3. Click on the "open file" button located at Save function frame 4. You can select either the SI units test file or the US English units file 5. Click the "open" button again 6. You must go through the steps accordingly and click all the "Done" and "Calculate buttons in order.
Troubleshooting Errors Errors that may occur and how to handle them Division by zero This error may occur under different conditions, if this error occur while thermal calculations are performed then check the figures you entered in to the data entry screens. It's more likely that you forgot to enter a figure or you entered an incorrect figure format. Make sure that all your text boxes are filled correctly and you are clicking all buttons in order.
Click on Calculate button and the results given is Zero Try to close the screen then reload it again and click the calculate button, this method will refresh the software controls.