Heat

Exchangers:
Introduction

Section 1: Heat Transfer

Overview
In this section, you will learn about heat transfer, including:

Conduction.
Convection.
Radiation.
Heat transfer through tubes.
Parallel flow and counter flow.

Heat Flow
Heat is a form of energy that is transferred from hot
to cold objects. When heating a home, for example,
it is important to efficiently transfer the heat from the
hot furnace to the cold rooms.
In a process plant, it is important to efficiently
transfer the heat from the hot product streams to
cold product streams.
When you touch a hot object, you feel the transfer of
heat because of the temperature difference between
your hand and the object. In fact, heat flow is much
the same as when water flows through a series of
connected vessels.

Heat energy always flows from a:

Colder object to a warmer object.
Warmer object to a colder object.

Answer

The colder object will

absorb heat from the
warmer object. The greater
the temperature difference
between objects, the faster
the heat transfer.

Conduction
Heat transfer by conduction occurs
within an object or between two
objects that are in direct contact
with one another. For example,
when a metal spoon is placed in a
cup of hot coffee, heat is
conducted from the hot coffee to
the spoon as long as there is
a temperature difference between
the coffee and the spoon. When
both objects reach the same
temperature, conduction stops.
Heat energy is the energy an
object has because the molecules
within the object are in
motion. When an object is heated,
the added energy causes its
molecules to move more rapidly.

Conduction occurs:
When there is no temperature difference between
objects.
If there is a temperature difference between objects.

Thermometers register
temperatures because of
conduction.

Answer

What type of heat energy travels through matter?

Convection.
Conduction.
Radiation.

Conduction occurs within an

object or between two
objects that are in direct
contact with each other.

Answer

Convection
When heat is transferred by
conduction, the molecules move a
short distance, passing along heat
energy from molecule to
molecule. Heat transfer
by convection is different. In
convection, the hot matter is
moved from a warmer area to a
colder area.
For example, when a pan of water
is placed over a flame, the heat
from the flame is transferred to
the bottom of the pan. Then, by
conduction, the heat is transferred
through the pan from molecule to
molecule.
When the bottom layer of water in
the pan is heated, it
expands. Because it expands, it
becomes lighter and rises in the
pan in a convection current. A
convection current is caused by
fluid expanding when it is heated,
rising, and becoming less
dense. Convection causes a
transfer of heat because the
warmer water rises in a convection
current and mixes with the cooler
water, just like a radiator works to
heat a room.
Heating a room with a space heater involves:
Convection.
Conduction.
Both of the above.

Answer

First, the air next to the

heater rises in a convection
current. Then, heat from
the warmed air is
transferred by conduction to
anything that comes into
contact with the air.

What type of heat energy does matter carry?

Convection.
Conduction.
Radiation.

Answer

A convection current carries

heat by the movement of
a liquid or gas from one
area to another. The
warmer, less dense
particles rise, while the
colder, denser particles
fall. This movement of
particles is what creates the
current.

Radiation
Heat energy can travel through matter (conduction)
or can be carried along by moving matter
(convection). Heat energy can also be transferred
through radiation.
Radiant heat energy travels in waves in the same
manner as light. Heat waves, like light waves, can
travel only in straight lines. For example, an electric
heater warms a room by using all three types of heat
transfer:

Radiation warms the air in front of the heater.

The warm air rises in a convection current.
Objects in the room are warmed by
conduction, if there is a temperature
difference between the object and the air.

For heat transfer by radiation to occur, the object

being heated must be directly in line with the source
that radiates the waves.

What type of heat energy travels in waves?

Convection.
Conduction.
Radiation.

Answer

Radiation transfers
heat through
electromagnetic waves:
visible light, infrared, and
ultraviolet light. These
waves travel in all
directions.

Heat Transfer Through Tubes

When the temperature of a fluid flowing inside a
tube is different from the temperature of the
atmosphere outside the tube, heat flows through
the tube wall. The amount of heat that flows
depends on the temperature difference between
the fluid and the outside atmosphere.
Typically, fluids flow in distinct ways:

Laminar flow: Fluids flow in smooth

streamlines.
Turbulent flow: Fluids flow with a great
deal of mixing.

Fluid flow can affect heat transfer. For example,

as the fluid flows, the molecules of the fluid rub
against one another. The friction between
the molecules causes resistance, which tends to
slow down flow.

In turbulent flow, the flow closest to the tube wall is:

Turbulent.
Laminar.

Answer

The fluid that is flowing

closest to the wall is
laminar. The friction of the
fluid closest to the tube wall
causes fluid to flow slowly.

This slow-flowing fluid acts as a static film covering the tube wall. Heat travels through
the tube walls by conduction, and for the heat to reach the mainstream, it must pass
through the static film by conduction.
In a turbulent stream, the fluid molecules mix to a great extent. As the mixing process
continues, many fluid molecules come in contact with the static film.
When these fluid molecules come in contact with the
static film, they _______ heat.
Absorb.
Give off.

Answer

The molecules that have

absorbed heat from the
static film transfer some of
the heat to other molecules
in the mainstream. Heat is
transferred to the molecules
by conduction.

In turbulent flow, the transfer of heat from the

static film to the mainstream is by conduction and
convection. Fluid farther from the tube wall flows
faster. The fluid that is flowing the fastest is in
the center of the mainstream.
Fluid in laminar flow acts much as if it consisted
of many thin-walled tubes of the fluid, one inside
the other.
For the mainstream to absorb heat, the heat must be conducted from layer to layer.
A fluid can be expected to absorb heat at a faster
rate in _______ flow.
Turbulent.
Laminar.

Answer

In comparison to metals,
fluids are poor
conductors. The time it
takes for heat to transfer
through the static film is
greater. The thicker the
static film, the greater the
heat transfer time.

Heat transfer time can be decreased by

decreasing the thickness of static film. The
thickness of static film depends on the
amount of turbulence. When turbulence is
slight, the static film is thick. As turbulence
becomes greater, the static film becomes
thinner.
Heat transfer time through static fluid can
be decreased by increasing fluid turbulence.
Different fluids are flowing on both sides of
a tube. The friction from the outside fluid
on the tube wall causes the fluid closest to
the wall to flow slowly.
The fluid closest to the tube wall becomes a
static film.

The greater the turbulence outside the tube, the

_______ the static film.
Thinner.
Thicker.

The greater the turbulence

outside the tube, the more
molecules come in contact
with the static film.

Answer

Factors Affecting Heat Flow

The factors affecting heat flow inside and
outside the tubes are similar. Examine
this example.

The temperature inside the tube

(T1) is higher than the temperature
outside the tube (T8).
The segment between T2 and T3
represents the temperature drop
across the inside fluid film.
T3 to T4 is the temperature drop
across the inside scale or fouling
material.
T4 to T5 is the temperature drop
through the tube wall.
T5 to T6 is the drop through the
outside fouling material.

Compared to the drop from T2 to T3, the drop from T4

to T5 is:
Steeper.

Less steep.

The temperature drop

through the tube wall is
close to zero.

Answer

The temperature drop is greater:

Through the inside and static films.
Through the tube wall.

The shape of the outside

temperature curve is similar
to the shape of the inside
temperature curve.

Answer

Counter Flow
In this kind of flow, the fluids flow in
opposite directions, or counter flow, which is
the most efficient flow. Suppose that the
two fluids are in counter flow inside and
outside a tube, and the hotter fluid is inside.
The temperature of the hotter inside fluid is
greatest at A. The temperature of the inside
fluid decreases in the direction of A to C.

The outside colder fluid is coolest at:

A.
B.

The outside fluid is warmest

at A.

C.

Answer

This graph shows the temperature in

relation to the length of the tube. In
counter flow, the temperature difference
along the tube is more constant than
the temperature difference in parallel
flow.
The heat transfer rate in counter flow
varies little over the length of the
tube. Notice the area on the graph that
is represented with a double arrow.

10

Counter flow _______ cooling a fluid to a

temperature lower than the highest temperature of
the cooling fluid.
Prevents.
Permits.

Answer

Review
In this section, you learned about heat transfer, including:

Conduction.
Convection.
Radiation.
Heat transfer through tubes.
Parallel flow and counter flow.

11

Section 2:

Heat Exchange Tubes

Overview
In this section, you will learn about heat exchange tubes, including:

Heat exchanger equipment.

Tube bundles.
Tube sheets and joints.
Tube sheet layouts.

12

Heat Exchanger Equipment

A simple heat exchanger is a set of steel
tubes enclosed in a tank. The tank
represents the shell of the exchanger and,
in this case, is filled with water.
Heat is transferred from the hot oil flowing
through the tubes to the cool water around
the tubes. The conductor of the heat is the
tube wall. The shell-side of an exchanger is
the area inside the shell and outside the
tubes. The tube-side of an exchanger is
the area inside the tubes.
In this example, the shell-side fluid is:
Oil.
Water.

The tube-side fluid is oil.

Answer

Examine the construction of a

typical shell-and-tube exchanger.
The tubes are anchored between two tube sheets. The combination of tubes and tube
sheets is called a tube bundle.

13

Shell-and-Tube Flow Path

Examine the fluid flow path
through a shell-and-tube
exchanger.
Hot process fluid flows into
the tube-side inlet, through the
tubes, and out through the tubeside outlet.
Cool water flows into the shell-side
inlet, around the tubes, and out
through the shell-side outlet.

In this example, heat is transferred from:

Shell to tube side.
Tube to shell side.

Answer

Tube Bundle
The greater the surface area of a conductor,
the more quickly heat is conducted. A bundle
of small tubes has more surface area than a
single large tube.
Shell-and-tube exchangers use a bundle of
small tubes, rather than a large, single tube.
Exchanger tubes can be either plain or
finned. As these drawings show, fins can be
inside or outside of the tubes.
Fins _______ the rate of heat transfer.
Increase.
Decrease.

Fins add to the tube surface

area, so they increase the

14

rate of heat transfer.

Answer

For exchangers that must handle corrosive fluids, tubes are sometimes made of
corrosion-resistant metal.
The outside diameters of tubing range from 1/4 inch to 2 1/2 inches (6 mm to 64
mm). The most common outer diameters include:

/2 inch (13 mm).

/4 inch (19 mm).
1 inch (25 mm).
3

Tubes with outer diameters at the extremes of the range (either high or low) are
usually produced in fewer gauges than the more common sizes.
Tubing with a 2 1/2 inch (64 mm) outer diameter is
usually produced in:
Many gauges.
One gauge.

Answer

Exchangers are usually produced in standard lengths of 8, 10, 12, 16, and 20 feet (2.4,
3.0, 3.7, 4.9, and 6.1 meters). Sixteen and 20 feet (4.9 and 6.1 meters) are the most
common lengths.
The particular application usually determines the length of the exchanger. Exchanger
design is determined by cost and the particular operating procedure.
As the length of the exchanger increases, its cost
generally:
Increases.
Decreases.

Exchangers must be
designed to meet operating
requirements while
minimizing costs.

Answer

15

Tube Sheets and Joints

Tube Sheets
The tube bundle is made by fastening the tube
ends into the openings in the tube
sheet. Because the tubes cannot move in the
tube sheets, the tube sheets and tubes form a
solid unit.
In some exchangers, the tubes and tube sheets
are fixed to the shell, so they are prevented from
moving.

Heat causes metals to expand. When the tubes

expand because of heat, stress is placed on the
tubes and the tube sheets.
A tube can come loose, allowing fluid to leak
between the tube wall and the opening in the
tube sheet. This means that the fluids may
contaminate one another.

To guard against this, a double tube sheet can be used in

cases where a leak absolutely cannot be tolerated.
For example, this design helps reduce the possibility of
leaks at the tube sheet. This design provides for a space
between the tube sheets.

16

If a leak occurs, fluid passes into this space.

Because the space between the tube sheets is open,
fluid is allowed to _______ the exchanger.
Collect in.
Drain from.

Answer

Tube Joints
The tube joint is the connection between the tube
and the tube sheet. The better the fit at the tube
joint, the less the possibility of leakage.
Tube joints are made with a rolled press-fit or are
welded. Some metals cannot be welded, so tubes
made of these metals are rolled. Rolled joints
usually make a very good seal, and they can be
used in reasonably high-pressure service, up to
about 2,000 PSI (13,790 kPa).
However, in special cases or severe service,
welded tube joints are usually used.
An exchanger is likely to be more expensive if the
tube joints are:
Welded.
Rolled press fit.

Welded joints are used in

most severe service
applications.

Answer

17

Tube Sheet Layout

Exchanger tubes can be installed in a
variety of patterns.
For example, when the tubes are arranged
in parallel rows, vertically and horizontally,
the pitch is called an in-line pitch.
The in-line square pitch offers the least
resistance to shell-side flow through an
exchanger. The greater the resistance to
flow, the greater the resulting pressure
drop.
For this reason, in-line square pitch is
particularly efficient when conditions
require a low pressure drop.
Staggering the tubes (as in the other main types of
pitch) allows _______ tubes in a given area than the
even spacing in square pitch.
More.
Fewer.

Answer

Passes Through Different Layouts

Compare the number of tubes in a given area in square pitch and triangular pitch.

Shell ID
(inches/cm)

Square Pitch

Triangular Pitch

Number of Passes

Number of Passes

20/51

241

263

224

269

260

250

22/56

300

280

280

337

330

314

24/61

360

350

336

421

404

380

26/66

424

412

402

499

476

460

28/71

402

488

480

579

562

542

30/76

580

566

566

668

648

636

18

32/81

665

648

644

766

744

732

34/86

756

758

730

870

850

834

36/91

853

848

832

986

978

942

38/97

973

950

938

1108

1100

1060

40/102

1085 1064 1052

1236

1228

1200

42/107

1201 1176 1162

1367

1350

1322

In a 42-inch (107 cm) double-pass exchanger, there

are _______ tubes in a square-pitch arrangement.

Answer

There are 1,350 tubes in a

triangular pitch. The more
tubes there are in a given
area, the higher the heat
transfer rate.

Because the square-pitch arrangement results in the lowest number of tubes in a given
area, it also results in the lowest heat transfer rate.
The pressure drop is higher when the pitch is:
Square.
Triangular.

Answer

When the pitch is

triangular, the pressure
drop is higher than when
the pitch is square. But,
the heat transfer rate is
greater when the pitch is
triangular.
For a given set of operating
conditions, the choice of
pitch arrangement depends
upon what pressure drop is
needed in relation to the
heat transfer rate desired.

19

Review
In this section, you learned about heat exchange tubes, including:

Heat exchange equipment.

Tube bundles.
Tube sheets and joints.
Tube sheet layouts.

Section 3: Heat Exchange Baffles and Surface

Area

20

Overview
In this section, you will learn about baffles and surface area, including:

Segmental baffles.
Disc/doughnut and impingement baffles.
Longitudinal baffles.
Effective heat transfer surface.

Segmental Baffles

The longer the tubes are in a heat

exchanger, the heavier they are. The heavier they are, the more likely they are
to sag. By preventing sagging, baffles also help maintain the tubes designed pressure
drop.
Baffles support the weight of the tubes and help to decrease stress on the tubing
and tube sheet

Baffle Positions
A segmental baffle is a circle from
which either a vertical or horizontal
portion has been cut.
In this case, the baffles are
vertically-cut segmental baffles.
Segmental baffles are positioned so
that the cut-out areas face in
alternate directions. This causes
flow to cross the tubes a number of
times, increasing the number of
contacts between the fluid and the
tubing. This increases the heat
transfer rate and ensures turbulent
flow of the shell-side fluid. It also provides better support for the tubes.

21

In addition to the portion cut from the

side or top of a segmental baffle, a
portion is often removed from the
bottom.

Removing this portion _______ some continuous

fluid flow along the bottom of the exchanger.
Prevents
Allows

Answer

Whether the baffle is cut vertically or

horizontally depends on the type of fluid and on
the operation. The horizontal baffle is most
likely to catch suspended materials:

22

For example, suppose the horizontal

baffles are used in
a condenser. Condensed fluid
builds up behind baffles A and C,
and restricts flow.

Then, the exchanger efficiency is:

Increased.
Decreased.

Efficiency is decreased
when drainage is
prevented.

Answer

Disc/Doughnut and Impingement Baffles

Disc/Doughnut Baffles
The pattern of flow through disc
and doughnut baffles is relatively
uniform. But if the fluids are not
clean, sediment builds up behind
the doughnut.

Which is used more frequently?

Segmental baffles.
Disc and doughnut baffles.

Because the cutout area of

23

Answer

the baffle in a disc and

doughnut baffle is in the
center, the flow of
condensed fluids along the
bottom of the exchanger
can be restricted.

Impingement Baffles
At high inlet-fluid velocities, the fluid can
seriously erode the tubes as it strikes
them. If the inlet fluid contains suspended
solid particles, the problem is more severe.
Impingement baffles are sometimes placed
at inlet flow areas to the shell-side.

The impingement baffle helps to _______ fluid flow.

Contain.
Spread out.

An impingement baffle
directs the flow toward the
sides of the exchanger.

Answer

The baffle effectively reduces tube erosion. In addition to reducing erosion, spreading
the fluid ensures that the fluid contacts all the tubes.
Increasing fluid-tube contact _______ the heat
transfer rate.
Decreases.
Increases.

Answer

24

Longitudinal Baffles
Longitudinal baffles are used to split shellside flow into two or more passes. The
longitudinal baffle is somewhat shorter
than the exchanger.
This allows for a double pass through the
exchanger.

Three longitudinal baffles provide for

_______ passes through the exchanger.

Answer

Three longitudinal baffles allow four passes

through the exchanger:

25

Examine this baffle position for divided flow.

Fluid flow on the two sides of the tubes is:

Consecutive.
Simultaneous.

Answer

Effective Heat Transfer Surface

The heat transfer surface depends on the:

Number of tubes.
Tube length.
Tube outside diameter.

As these factors increase, effective heat transfer surface also increases.

The entire length of a tube is not the effective length of the tube. Because the tube
extends through the tube sheet at each end of the exchanger, the effective length is
shorter than the actual length.
For 15-foot (4.6-meter) tubes extending 3 inches (7.6 cm) through a tube sheet at
each end, the effective length is about 14.5 feet (4.4 meters) minus 6 inches (0.15 m),
or:

26

The formula for calculating exchanger effective tube surface is:

If the square foot (meter) of external surface per

length is 0.2618 (0.0243 m2), the net effective tube
length is 15.5 feet (4.7 meters), and there are 682
tubes, then the effective tube surface is:
167.98 feet2 (15.6 meters2).
2,767.49 feet2 (77.9 meters2).

Answer

Review
In this section, you learned about baffles and surface area, including:

Segmental baffles.
Disc/doughnut and impingement baffles.
Longitudinal baffles.
Effective heat transfer surface.

27

Section 4:

Shell-and-Tube Exchangers

Overview
In this section, you will learn about shell-and-tube exchangers, including:

Shell-and-tube flow arrangements.

Fixed tube sheets and U-tube exchangers.
Floating head exchangers.
Size numbering and type designation.

Shell-and-Tube Flow Arrangements

Shell-Side Flow Arrangements

28

Shell-side flow arrangements include:

One-pass shell: the shell-side fluid enters one end of the exchanger, flows
through the exchanger, and exits through the opposite end.
Double pass: requires that the fluid enter and exit through the same end.
Split flow: divides incoming shell fluid into two separate streams.
Double split flow: divides shell fluid into four separate streams.
Divided flow: the shell fluid enters at the center of the exchanger, rather than at
the end.
Kettle-type reboiler: has divided flow and a dome outlet for vapors.

The choice of shell arrangement depends on the amount of cooling or heating required,
on the pressure drop required, and on the type of service.
The shell arrangement that provides space for vapors
to accumulate is the:
One-pass shell.
Split flow.
Kettle-type reboiler.
Double split flow.

The effective time that the

shell-side fluid is in contact
with the tubes increases as
the number of passes
increases.

Answer

Tube Flow
Flow arrangement can be changed
through both the shell and the tubes. A
channel head baffle can be built into the
head end of the exchanger to direct the
flow through the first half of the tubes in
one direction, and the second half of the
tubes in the opposite direction.
This is a single-pass tube
arrangement. Tube-side fluid enters one
end of the exchanger, flows through the
tubes in the same direction, and leaves at
the opposite end of the exchanger.

29

A tube-side baffle can be built into the head

end of the exchanger to direct flow through
the tubes.
In a two-pass arrangement, fluid flows
through half the tubes in one direction and
the other half of the tubes in the opposite
direction.
This requires one channel head baffle and no
floating head baffle.

The channel head baffle in a two-pass tube

arrangement is positioned:
Vertically.
Horizontally.

Answer

Compare the two-pass arrangement with the fourpass arrangement. Which requires two channel head
baffles and one floating head baffle?

30

Four-pass.
Two-pass.

Increasing the number of

passes requires increasing
the number of baffles.

Answer

Fixed Tube Sheet and U-Tube Exchangers

Fixed Tube Sheet Exchangers
In the fixed tube sheet exchanger, the tube sheet
is welded to the shell. The tube bundle is
permanently installed.

Fixed tube sheet exchangers are used when the

temperature range is:
Narrow.
Wide.

Answer

Expansion and contraction

due to temperature changes
place stress on the tube
bundle. Because this tube
bundle is prevented from
expanding, large
temperature fluctuations
should be avoided.

Examine the expansion joint built into the

shell of a fixed tube sheet exchanger. As
the tubes become hotter, they expand. The
built-in joint allows the shell to expand also.
As the tubes and shell cool, the expansion
joint and tubes contract. Stress on the
welding and on the tubes and shell is
decreased.
Because of inspection and cleaning difficulties, fixed
tube sheet exchangers are generally used where

31

shell-side fouling is:

Extensive.
Limited.

Answer

Because the tube bundle

cannot be removed from
the shell, the shell-side of a
fixed tube sheet exchanger
must be cleaned chemically.

U-Tube Exchangers

A U-tube exchanger
has only one tube sheet. A channel baffle is bolted between the tube sheet and the
channel cover.
The tube sheet and tube bundle form a unit. By unbolting the channel from the shell,
the tube sheet and tube bundle can be removed from the shell so that the outside of
the tubes can be cleaned. However, the bend in the tubes inhibits cleaning and
inspecting the inside of the tubes.

32

Examine the flow pattern in a U-tube exchanger. The baffle dividing the channel
directs incoming tube-side fluid through only the upper half of the tube openings.
Because the tube bundle in a U-tube exchanger is
fastened to only one tube sheet, the tubes are:
Prevented from expanding.
Free to expand.

Answer

U-tubes can also be used

where the temperature
difference between shellside and tube-side fluid is
quite large.

In this case, tube-side flow is:

Two-pass.
One-pass.

Shell-side flow is onepass.

Answer

Floating Head Exchangers

The main types of floating head exchangers include:

Pull-through type.
Split backing-ring type.

Pull-Through Type
In this exchanger, the tube sheet
on the right is bolted between the
channel and shell in a fixed
position. But the tube sheet on the
left, together with the cover, floats
inside the shell, free to move
horizontally. This tube sheet, along
with its cover is known as a floating
head.

33

Is there vertical movement in this exchanger?

Yes.
No.

Answer

Because of tube
bundle weight, there is no
vertical movement. But
because the tube bundle
and floating head can move
horizontally, the tubes are
free to expand and
contract.

After unbolting the channel

flange and the stationary tube
sheet, the tube bundle and the
floating head can be
withdrawn as a unit.
This allows the outside of the
tubes to be cleaned and
inspected.
Now, notice that
this channel
cover, shell cover,
and floating head
cover have been
removed. This
provides access to
both tube sheets
and to the insides
of the tubes. This
way, the inside of
the tubes can be
cleaned and
inspected.
The clearance space between the shell and tubes
_______ efficiency of the pull-through exchanger.

34

Increases.
Decreases.

Answer

The clearance is large and

is necessary to
accommodate the outside
diameter of the floating
tube sheet. Because no
tubes can occupy this
space, the space is
wasted. Also, fluid is likely
to move through the space
rather than past the tube
bundle, so the clearance
space reduces efficiency.

Split Backing-Ring Type

In this floating head exchanger, the diameter of the shell cover is greater than the

35

diameter of the rest of the shell holding the tubes.

The tubes, tube sheet, and floating head cover cannot be pulled through the channel as
a unit.
To pull the tube bundle of the split backing-ring type, the floating head cover, shell
cover, and the split ring must be removed first. But, clearance between the tube
bundle and shell is smaller in the split backing-ring exchanger.
If the same amount of space is available, more tubes can be used in the split backingring exchanger.
Compare the split backing-ring exchanger and the
pull-through exchanger. Which can be pulled
through the channel as one unit?
Pull-through exchanger.
Split backing-ring exchanger.

Answer

An advantage of the pullthrough exchanger is that

the bundle and head can be
pulled through the channel
as one unit.

The split backing-ring exchanger is more difficult to disassemble. First, the shell cover
is unbolted from the shell. Then, the floating head cover and split backing-ring are
unbolted from the floating tube sheet. Next, the channel is unbolted from the other
end of the shell. Finally, the tube is pulled from the channel end.
Because disassembly is more time consuming, it is also more costly.
Which is more efficient?
Pull-through exchanger.
Split backing-ring exchanger.

The split backing-ring

exchanger is more efficient,
but has more parts. So, it
is more expensive to build.

Answer

Size Numbering and Type Designation

Exchanger size is specified by the Tubular Exchanger Manufacturer's Association
(TEMA), and depends on the diameter of shell and length of tubes, in inches
(centimeters).
Because shell diameter is specified first, a size 23-192 exchanger has a diameter of 23

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inches / centimeters and tubes that are 192 inches / centimeters long.
When the shell diameter is between two numbers, such as 33 1/4 inches / centimeters,
it is rounded to the nearest whole number.
An exchanger with a 33 1/4 inch / centimeter
diameter and 188-inch / centimeter long tubes is
designated size:
33-188.
34-188.

Answer

Type Designation
Type designation includes the:

Type of stationary head.

Shell type.
Type of rear head.

Designations are specified by letters. Notice that the four designations of stationary
head types are indicated by A, B, C, and D.

Review
In this section, you learned about shell-and-tube exchangers, including:

Shell-and-tube flow arrangements.

Fixed tube sheets and U-tube exchangers.
Floating head exchangers.
Size numbering and type designation.

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Special high-pressure stationary head closures are

indicated by:
A.
B.
C.
D.

Answer

Shell types are indicated by

E, F, G, H, J, and K. Rear
head types are specified as
L, M, N, P, S, T, and U.
An example of a complete
exchanger designation is
size 17-192 type AES. This
exchanger has a 17-inch /
cm diameter and 192-inch /
cm long tubes.

An exchanger designated as 17-192 type AES has

a(n):
Integral cover.
Removable channel and cover.

It has a one-pass shell and

a floating head with a
backing device.

Answer

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Glossary
Baffle
A partial restriction, generally a plate, located in a tank or vessel used to aid in heat transfer by
changing direction, guiding flow, or promoting mixing within the equipment.

Condenser
A heat exchanger which removes heat from a vapor, causing it to condense into a liquid or twophase mixture.

Conduction
Heat transfer within an object, or from a warmer object to a colder one through direct contact.

Convection
Heat transfer from one place to another by moving warmed fluids (liquid or gas).

Cooling Tower
A structure used to cool water by evaporation. Cooling towers usually have induced-draft or forceddraft type fans for supplying air and speeding evaporation.

Corrosion
Complex chemical or electrochemical process by which metal is worn away and destroyed through
reaction with its environment. Rust on steel is a product of corrosion.

Counter Flow
A system where a fluid flows in one direction and another fluid flows in the opposite direction.

Density
Mass of a substance per unit of volume, or the heaviness of a substance.

Energy
The capacity to do work or cause heat flow.

Evaporation
The process of molecules leaving a liquid in vapor form. Also called vaporization.

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Expansion
The act of increasing in size or volume.

Fixed Tube Sheet Exchanger

A shell-and-tube type of heat exchanger where the tube sheet does not allow for expansion.

Floating Head Heat Exchanger

A shell-and-tube type of heat exchanger with a tube sheet fixed at one end. The tubes can be
removed for cleaning and allow for expansion.

Flow
Fluid movement from one place to another caused by pressure differences.

Fluid
Any substance that flows and has no definite shape.

Fouling
The buildup of scale or other deposits on equipment or in piping. In heat transfer, a fouling layer on
surfaces acts as an additional layer of insulation, reducing heat transfer.

Friction
The force that resists motion between bodies in contact with one another.

Heat
Form of energy. Measure of the kinetic energy of the molecules of a substance.

Heat Energy
The energy an object has because the molecules within the object are in motion.

Heat Exchanger
Equipment designed to transfer heat from one fluid to another.

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Heat Transfer
The movement of heat from a warmer to a cooler substance. Energy in transport from a substance
of higher temperature to a substance of lower temperature. The term "heat" is commonly used in
place of the term thermal energy, however heat only exists as energy in transit.

Joule (J)
A unit of work or energy, equal to the force of one newton moving an object a distance of one meter.
One joule per second equals one watt. As a unit of energy, it is the amount of energy required to
raise the temperature of one kilogram of water 1 C.

Laminar Flow
Smooth or streamline flow in piping, occurring at low velocities.

Molecule
The smallest particle of a substance that retains the properties of the substance and is composed of
one or more atoms.

Newton (N)
A unit of force, equal to the force required to accelerate one kilogram one meter per second
squared.

Parallel Flow
A system where the streams of fluids are flowing in the same direction.

Pascal (Pa)
A measurement of pressure equal to the pressure of the force of one newton (N), acting equally over
an area of one square meter. 1,000 pascals equals 1 kilopascal (1 kPa).

Pounds per Square Inch (PSI)

A measurement of pressure calculated as force (in pounds force) divided by area (in square inches).
In metric units, pressure is measured in kilopascals (kPa), or force (newtons) per unit of area (one
square meter).

Pressure Drop
The decrease in pressure due to frictional losses which occurs when a liquid or gas passes through
a pipe, vessel, orifice plate, control valve, or other piece of equipment.

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Radiation
Heat transfer by electromagnetic waves in a straight line in all directions, including visible, infrared,
and ultraviolet light.

Scale
Substances released from oversaturated water. These substances will settle on the sides of a
pipeline or equipment and may cause a blockage.

Shell-and-Tube Heat Exchanger

Type of heat exchanger consisting of a number of parallel tubes enclosed within a shell. The shellside fluid flows outside the tubes in the shell, while the tube-side fluid flows through the tubes.

Shell-Side Fluid
The fluid that flows inside the shell, but outside the tubes in a shell-and-tube heat exchanger.

Stream
Fluid entering or leaving a process unit.

Suspended Solids
Solid materials dispersed in water, such as sand, loose corrosion, scale products, and sludge.

Temperature
An indication of the average thermal/internal energy in a substance. Temperature is often reported
in degrees Fahrenheit ( F) or degrees Celsius ( C).

Thermal Conductivity
The rate at which a substance conducts heat.

Tube Bundle
A group of parallel tubes used in a heat exchanger. The tube bundle includes the tube sheets
containing the tubes, the baffle, and the spacer rods.

Tube Joint
The connection between the tube and the tube sheet.

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Tube Pitch
The tube pattern arrangement in a heat exchanger, including square, triangular, or diagonal square
pitch.

Tube Sheet
The part of a heat exchanger where the tubes attach.

Tube-Side Fluid
The fluid that flows inside the tubes (not the shell) in a heat exchanger.

Turbulent Flow
A swirling, agitated, or choppy flow through a pipe or conduit, usually occurring with high velocity
flows.

U-Tube Heat Exchanger

A shell-and-tube type heat exchanger where the tube sheet is fixed at one end.

Velocity
Measurement of the speed of flow; usually specified in units of feet per second (meters per second).

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