Heat Exchanger Thermal Design Hetran 11.

1 Page 1
File: SC1.BJT Date: 7/22/2016 Time: 7:01:26 AM
Description
Heading
Company: M/s.Avra
Location: Hyderabad
Service of Unit: sub cooler Our Reference: Santhosh/ Raja
Item No.: HE-103 Your Reference:
Date: 25.05.101 Rev No.: 00 Job No.:
Hot Side Cold Side
Fluid name MIBK cooling water

Remarks

Application Options
Hot side application Liquid, no phase change
Condensation curve Specified in input
Condenser type Normal

Cold side application Liquid, no phase change

Vaporization curve Specified in input
Vaporizer type Forced circulation

Location of hot fluid Shell side

Program mode Design

Process Data
Hot Side Cold Side
In Out In Out
Fluid quantity, total kg/h 910
Vapor quantity kg/h 22
Liquid quantity kg/h 22
Temperature C 64.9 41 35 40
Dew / Bubble point C 38.25
Operating pressure (absolute) mmHq 760 1471.12

Heat exchanged kcal/h

Allowable pressure drop kgf/cm2

Fouling resistance ft2*h*F/BTU 0.001 0.003

Heat Load Balance Options Program Program

Databanks

Hot Side Use properties from the following:

Cold Side Use properties from the following:

Aspen Plus or Aspen Properties run file

Hot side composition specification Weight flowrate or %

Cold side composition specification Weight flowrate or %
Heat Exchanger Thermal Design Hetran 11.1 Page 2
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Hot Side - Component
Components Source Vapor in Liquid in Liquid out Component
type
Water Databank 0 Program
Methanol Databank 100 Program

Hot Side - Liquid Properties

Temperature Specific heat Thermal Viscosity Density Surface
cond. tension

C kcal/(kg*C) kcal/(h*m*C) cp kg/m3 dynes/cm

Cold Side - Component

Components Source Liquid in Vapor in Vapor out Component
type
water Databank Program
Heat Exchanger Thermal Design Hetran 11.1 Page 3
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Cold Side - Liquid Properties
Temperature Specific heat Thermal Viscosity Density Surface
cond. tension
C kcal/(kg*C) kcal/(h*m*C) cp kg/m3 dynes/cm

Exchanger Type
Front head type B - bonnet bolted or integral with tubesheet
Shell type E - one pass shell
Rear head type M - bonnet
Exchanger position Vertical

Front cover type Program Rear cover type Program

Cover welded to a cylinder Program Cover welded to a cylinder Program
Shell cover type Program

Tubesheet type Program Flange type - hot side Program

Tube to tubesheet joint Program Flange type - cold side Program
Include expansion joint Program

Tubes
Tube type Plain Fin height mm
Tube outside diameter 19.05 mm Fin thickness mm
Tube wall thickness 1.6 mm Fin density #/m
Tube wall specification Average Surface area per unit length m
Tube material SS 316 Outside/Inside surface area ratio
Tube pattern Triangular
Tube pitch 25 mm

Twisted tape ratio

Twisted tape width mm
Tapered tube ends for knockback condensers
Heat Exchanger Thermal Design Hetran 11.1 Page 4
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Bundle

Pass layout Program will optimize Open space between shell ID and outermost tube
Impingement protection type Program PercShellID Distance
Outer tube limit diameter mm at top, S1 mm
at bottom, S2 mm
at sides, S3 mm
Pool boiler options
Provide disengagement space in shell 1
Percent of shell diameter for disengagement

Shell entrance construction Normal with full layout

Shell exit construction Normal with full layout

Diametric clearances Design symmetrical tube layout

Shell ID to baffle OD mm Maximum % deviation in tubes per pass
Baffle OD to outer tube limit mm Number of tie rods
Baffle tube hole to tube OD mm Number of sealing strip pairs
Pass partition lane width mm Minimum u-bend diameter mm

Baffles
Number of intermediate supports
Baffle type Single segmental
at inlet
Baffle cut (% of diameter) 25
at outlet
Baffle cut orientation Horizontal

Number of supports at u-bend

Rating/Simulation

Shell outside diameter 325 mm Kettle outside diameter mm

Shell inside diameter mm Kettle inside diameter mm
Baffle spacing center-center 250 mm
Baffle spacing at inlet mm Vapor belt outside diameter mm
Baffle spacing at outlet mm Vapor belt inside diameter mm
Baffle number 6 Vapor belt length mm
Tube length 2000 mm
Tube number 48 Shell cylinder thickness mm
Tube passes 8 Front head cylinder thickness mm
Shells in series Front tubesheet thickness mm
Shells in parallel Rear tubesheet thickness mm
Baffle thickness mm

Nozzles
Diameter Quantity Orientation Dome OD
mm mm
Hot Side Inlet
Hot Side Outlet
Hot Side Condensate
Cold Side Inlet
Cold Side Outlet
Heat Exchanger Thermal Design Hetran 11.1 Page 5
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Nozzles
Hot Side Cold Side
Nozzle flange rating Program Program
Nozzle flange type Program Program

Flow direction for first tube pass Program

Location of nozzle at u-bend Program

Design Constraints
Increment Minimum Maximum
Shell diameter mm
Tube length 2000 mm
Tube passes Program
Baffle spacing 250 250 mm

Use shell ID or OD as reference Program Allowable number of baffles Program

Use pipe or plate for small shells Program Allow baffles under nozzles Program
Minimum shells in series Use proportional baffle cut Program
Minimum shells in parallel

Hot Side Cold Side

Allowable pressure drop kgf/cm2 kgf/cm2
Minimum fluid velocity m/s m/s
Maximum fluid velocity m/s m/s

Minimum % excess surface area required

Materials
Cylinder - hot side SS 316
Cylinder - cold side SS 316
Tubesheet SS 316
Double tubesheet (inner) SS 316
Baffles Carbon Steel
Tube material SS 316

Thermal conductivity of tube material kcal/(h*m*C)

Tubesheet cladding - hot side

Tubesheet cladding - cold side
Gaskets - hot side
Gaskets - cold side

Specifications
Hot Side Cold Side
Design Code ASME Code Sec VIII Div 1 Design pressure kgf/cm2
Service class Normal Design temperature C
TEMA class B - chemical service Vacuum design pressure kgf/cm2
Material standard ASTM Test pressure kgf/cm2
Dimensional standard ANSI - American Corrosion allowance mm
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Thermal Analysis Options
Hot Side Cold Side
Heat transfer coefficient kcal/(h*m2*C)
Heat transfer coefficient multiplier 0.8 0.8
Pressure drop multiplier 1.2 1.2

Percent of u-bend area used for heat transfer

Maximum rating for thermosiphons Program

Mean temperature difference C

Minimum allowable temperature approach C
Minimum allowable MTD correction factor
Maximum allowable heat flux kcal/(h*m2)
Flow direction for first tube pass Program

Desuperheating heat transfer method Program

Condensation heat transfer model Program
Suppress nucleate boiling coefficient
Minimum temperature difference for nucleate boiling C
Tube side two phase pressure drop correlation Program
Simulation mode area convergence tolerance
Number of calculation intervals
Type of interval calculation Program

Change Codes
Heat Exchanger Thermal Design Hetran 11.1 Page 7
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Thermal Details - General

Shell Side Tube Side

Gases (in/out) kg/h
Liquids (in/out) kg/h 910 910 2934 2934
Temperature (in/out) C 64.9 41 35 40
Dew point or bubble point C

Film coefficient kcal/(h*m2*C) 232.5 1548.2

Fouling resistance m2*h*C/kcal 0.0002 0.00061
Velocity m/s 0.02 0.36
Pressure drop (allow./calc.) mmHq 304 3.32 517.15 18.25

Total heat exchanged kcal/h 14673 Type BEM vert 1 ser 1 par
Overall coef. - dirty kcal/(h*m2*C) 162.1 Shell size 266 2000 mm
Effective surface area m2 8.1 Tube No-OD 70 19.05 mm
MTD corrected C 11.39 Baffles single seg 27 % hor
MTD correction factor 0.86 Tube passes 6 mixed

Thermal Details - Thermal Resistances

Clean Spec. foul Max. foul

Area reqd. m2 6.7 7.9 8.1

Excess surface % 20.86 2.39

Overall coefficient kcal/(h*m2*C) 191.3 162.1 158.3

Overall resistance m2*h*C/kcal 0.00523 0.00618 0.00632

Shell side fouling m2*h*C/kcal 0.0 0.0002 0.00024

Tube side fouling (at tube ID) 0.0 0.00061 0.00071

Distribution of overall resistance

Shell side film % 82.3 69.72 68.09
Shell side fouling % 0.0 3.32 3.75
Tube wall 0.00015 % 2.85 2.41 2.36
Tube side fouling % 0.0 11.97 13.51
Tube side film % 14.85 12.58 12.29
Heat Exchanger Thermal Design Hetran 11.1 Page 8
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Thermal Details - Coefficients

Shell Side Tube Side

Film coefficients kcal/(h*m2*C)
As calculated by program 290.6 1935.3
As specified by user in input
User specified multiplier 0.8 0.8
As used in design 232.5 1548.2
Desuperheating coefficient
Condensing coefficient
Vapor sensible coefficient
Liquid sensible coefficient 232.5 1548.2
Boiling coefficient
Liquid cooling coefficient

Reynolds number 575.83 8183.22

Fin efficiency factor 1
Mean metal temperature C 53.13 41.53

Thermal Details - MTD and Flux

Mean temperature difference C Flux kcal/(h*m2)

Corrected MTD used in design 11.39 Actual flux 1803

LMTD 13.28 Boiling fluid

MTD correction factor
Long. baffle efficiency factor
Calculated corrected MTD
User specified corrected MTD
Flow direction
0.86 Nucleate maximum flux
Program maximum flux
11.39 Specified maximum flux
Controlling maximum flux
Heat Exchanger Thermal Design Hetran 11.1 Page 9
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Thermal Details - Pressure Drop

Shell Side Tube Side

Pressure Drop kgf/cm2

Allowable 0.413 0.703
Calculated, clean 0.005 0.025
Calculated, dirty 0.005 0.026
User specified bundle multiplier 1.2 1.2

Velocity and pressure drop distribution m/s %dp m/s %dp

Inlet nozzle 0.67 56.13 0.4 1.66

Entering bundle 0.02 12.1 0.36 9.29
Crossflow 0.02 0.7
Through baffle windows 0.04 1.12
Through tubes 0.36 78.07
Exiting bundle 0.02 11.74 0.36 9.31
Outlet nozzle 0.65 18.21 0.4 1.67

Thermal Details - Shell Side Stream Analysis

Shell Side Stream Analysis Flow fraction Diametric clearances

% mm

Crossflow 64.05
Clearance: Baffle hole - tube od 8 0.79
Clearance: Shell id - baffle od 12.02 3.18
Clearance: Shell id - bundle otl 15.92 9.52

Rho*V2 analysis Rho*V2 TEMA limit

kg/(m*s2) kg/(m*s2)

Inlet nozzle 332 2232

Shell entrance 90 5953
Bundle entrance 0 5953
Bundle exit 0 5953
Shell exit 87 5953
 Heat Exchanger Specification Sheet
1 Company: M/s.Avra
2 Location: Hyderabad
3 Service of Unit: sub cooler Our Reference: Santhosh/ Raja
4 Item No.: HE-103 Your Reference:
5 Date: 25.05.101 Rev No.: 00 Job No.:
6 Size 266 -- 2000 mm Type BEM vert Connected in 1 parallel 1 series
7 Surf/unit(eff.) 8.1 m2 Shells/unit 1 Surf/shell (eff.) 8.1 m2
8 PERFORMANCE OF ONE UNIT
9 Fluid allocation Shell Side Tube Side
10 Fluid name MIBK cooling water
11 Fluid quantity, Total kg/h 910 2934
12 Vapor (In/Out) kg/h
13 Liquid kg/h 910 910 2934 2934
14 Noncondensable kg/h
15
16 Temperature (In/Out) C 64.9 41 35 40
17 Dew / Bubble point C
18 Density kg/m3 749.76 772.52 996 994.43
19 Viscosity cp 0.363 0.49 0.72 0.653
20 Molecular wt, Vap
21 Molecular wt, NC
22 Specific heat kcal/(kg*C) 0.711 0.6408 1.0004 1.0002
23 Thermal conductivity kcal/(h*m*C) 0.169 0.176 0.528 0.534
24 Latent heat kcal/kg
25 Pressure kgf/cm2 1.033 2
26 Velocity m/s 0.02 0.36
27 Pressure drop, allow./calc. mmHq 304 3.32 517.15 18.25
28 Fouling resist. (min) m2*h*C/kcal 0.0002 0.00061
29 Heat exchanged 14673 kcal/h MTD corrected 11.39 C
30 Transfer rate, Service 158.3 Dirty 162.1 Clean 191.3 kcal/(h*m2*C)
31 CONSTRUCTION OF ONE SHELL Sketch
32 Shell Side Tube Side
33 Design/Test pressure kgf/cm2 5.273 -1.034 Code 5.273 Code
34 Design temperature C 98.89 76.67
35 Number passes per shell 1 6
36 Corrosion allowance mm
37 Connections In 25.4 150 ANSI 50.8 150 ANSI
38 Size/rating Out 25.4 150 ANSI 50.8 150 ANSI
39 mm Intermediate 150 ANSI 150 ANSI
40 Tube No. 70 OD 19.05 Tks-avg 1.6 mm Length 2000 mm Pitch 25 mm
41 Tube type Plain Material SS316 Tube pattern 30
42 Shell SS316 ID OD 273.05 mm Shell cover
43 Channel or bonnet SS316 Channel cover
44 Tubesheet-stationary SS316 Tubesheet-floating
45 Floating head cover Impingement protection None
46 Baffle-crossing CS Type single seg Cut(%d) 27 hor Spacing: c/c 249.94 mm
47 Baffle-long Seal type Inlet 346.58 mm
48 Supports-tube U-bend Type
49 Bypass seal Tube-tubesheet joint groove/expand
50 Expansion joint Type
51 RhoV2-Inlet nozzle 332 Bundle entrance 0 Bundle exit 0 kg/(m*s2)
52 Gaskets - Shell side Tube Side
53 Floating head
54 Code requirements ASME Code Sec VIII Div 1 TEMA class B
55 Weight/Shell 281.5 Filled with water 399.7 Bundle 146.2 kg
56 Remarks
57
58
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Calculation Details - Shell Side - Liquid Properties
Temperature Density Specific Thermal Viscosity
bulk wall heat conductivity bulk wall
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp
63.81 44.65 750.83 0.7075 0.169 0.368 0.469
61.64 44.05 752.96 0.7006 0.17 0.378 0.472
59.47 43.45 755.07 0.6938 0.17 0.388 0.476
57.3 42.85 757.17 0.6871 0.171 0.399 0.479
55.12 42.26 759.25 0.6805 0.172 0.41 0.483
52.95 41.66 761.32 0.6741 0.172 0.422 0.486
50.78 41.07 763.38 0.6677 0.173 0.434 0.49
48.6 40.49 765.43 0.6615 0.174 0.446 0.493
46.43 39.9 767.46 0.6555 0.174 0.459 0.497
44.26 39.31 769.49 0.6495 0.175 0.471 0.5
42.09 38.73 771.51 0.6437 0.176 0.484 0.504

Calculation Details - Shell Side - Heat Load

Temp. Flowrate Sensible heat Total
Liquid Liquid load
C kg/h kcal/h kcal/h
64.9 910
62.73 910 1399 1399
60.55 910 2784 2784
58.38 910 4156 4156
56.21 910 5514 5514
54.04 910 6860 6860
51.86 910 8193 8193
49.69 910 9513 9513
47.52 910 10821 10821
45.35 910 12117 12117
43.17 910 13401 13401
41 910 14673 14673
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Calculation Details - Shell Side - Performance
Vapor Heat load Overall Area reqd. Temperature Pressure
temperature coefficient difference drop
C % kcal/(h*m2*C) % C %
Inlet 64.9 68.23
62.73 9.53 163.2 9.47 11.39 0.08
60.55 9.44 163 9.39 11.39 0.09
58.38 9.35 162.7 9.31 11.39 0.21
56.21 9.26 162.5 9.23 11.39 0.21
54.04 9.17 162.2 9.16 11.39 0.21
51.86 9.08 162 9.09 11.39 0.21
49.69 9 161.8 9.01 11.39 0.2
47.52 8.91 161.6 8.94 11.39 0.2
45.35 8.83 161.4 8.87 11.39 0.2
43.17 8.75 161.2 8.8 11.39 0.1
41 8.67 161 8.73 11.39 0.07
excess area 0.04
Outlet 41 29.95

Calculation Details - Shell Side - Coefficients

Temp. Flowrate Velocity Coefficients
bulk Pr Re regime X-flow Window free forced Actual
C m/s m/s kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C)
63.81 5.54 661.28 Transition 0.02 0.04 144.4 293.6 234.9
61.64 5.62 643.78 Transition 0.02 0.04 143.1 292.9 234.3
59.47 5.7 626.34 Transition 0.02 0.04 141.8 292.3 233.8
57.3 5.78 609.12 Transition 0.02 0.04 140.4 291.7 233.3
55.12 5.86 592.25 Transition 0.02 0.04 139.1 291.1 232.8
52.95 5.95 575.83 Transition 0.02 0.03 137.8 290.5 232.4
50.78 6.04 559.92 Transition 0.02 0.03 136.6 289.9 231.9
48.6 6.13 544.59 Transition 0.02 0.03 135.3 289.3 231.5
46.43 6.22 529.88 Transition 0.02 0.03 134.2 288.8 231
44.26 6.31 515.74 Transition 0.02 0.03 133.1 288.3 230.6
42.09 6.4 502.18 Transition 0.02 0.03 132 287.8 230.2
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Calculation Details - Tube Side - Liquid Properties
Temperature Density Specific Thermal Viscosity
bulk wall heat conductivity bulk wall
C C kg/m3 kcal/(kg*C) kcal/(h*m*C) cp cp
35.23 39.67 995.93 1.0004 0.528 0.716 0.658
35.68 40 995.8 1.0004 0.529 0.71 0.654
36.14 40.33 995.66 1.0004 0.529 0.704 0.649
36.59 40.67 995.52 1.0004 0.53 0.697 0.646
37.05 41.01 995.39 1.0003 0.53 0.691 0.642
37.5 41.34 995.25 1.0003 0.531 0.685 0.638
37.95 41.68 995.11 1.0003 0.531 0.679 0.634
38.41 42.02 994.96 1.0003 0.532 0.673 0.63
38.86 42.36 994.81 1.0002 0.532 0.667 0.626
39.32 42.7 994.66 1.0002 0.533 0.662 0.623
39.77 43.03 994.51 1.0002 0.533 0.656 0.619

Calculation Details - Tube Side - Heat Load

Temp. Flowrate Sensible heat Total
Liquid Liquid load
C kg/h kcal/h kcal/h
35 2934
35.45 2934 1334 1334
35.91 2934 2668 2668
36.36 2934 4002 4002
36.82 2934 5336 5336
37.27 2934 6670 6670
37.73 2934 8004 8004
38.18 2934 9338 9338
38.64 2934 10672 10672
39.09 2934 12005 12005
39.55 2934 13339 13339
40 2934 14673 14673
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Calculation Details - Tube Side - Performance
Temp. Heat load Overall Area reqd. Temperature Pressure
coefficient difference drop
C % kcal/(h*m2*C) % C %
Inlet 35 10.96
35.45 9.09 161.6 9.12 11.39 7.02
35.91 9.09 161.7 9.11 11.39 7
36.36 9.09 161.8 9.1 11.39 6.98
36.82 9.09 161.9 9.1 11.39 6.96
37.27 9.09 162 9.09 11.39 6.95
37.73 9.09 162.1 9.09 11.39 6.93
38.18 9.09 162.2 9.09 11.39 6.91
38.64 9.09 162.2 9.08 11.39 6.9
39.09 9.09 162.3 9.08 11.39 6.88
39.55 9.09 162.4 9.07 11.39 6.87
40 9.09 162.5 9.07 11.39 6.85
excess area 1.82
Outlet 40 10.97

Calculation Details - Tube Side - Coefficients

Temp. Flow Velocity Coefficients
bulk Pr Re regime free forced Actual
C m/s kcal/(h*m2*C) kcal/(h*m2*C) kcal/(h*m2*C)
35.23 4.89 7825.23 Transition 0.36 1894.1 1515.2
35.68 4.84 7896.14 Transition 0.36 1903.8 1523.1
36.14 4.79 7967.48 Transition 0.36 1913.6 1530.9
36.59 4.75 8039.08 Turbulent 0.36 1922 1537.6
37.05 4.7 8110.95 Turbulent 0.36 1929.4 1543.5
37.5 4.65 8183.22 Turbulent 0.36 1936.7 1549.3
37.95 4.61 8255.05 Turbulent 0.36 1944 1555.2
38.41 4.57 8326.43 Turbulent 0.36 1951.2 1560.9
38.86 4.52 8398.21 Turbulent 0.36 1958.4 1566.7
39.32 4.48 8470.06 Turbulent 0.36 1965.6 1572.5
39.77 4.44 8541.98 Turbulent 0.36 1972.8 1578.2
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Calculation Details -

Exchanger Clean Dirty

Heat exchanged kcal/h 15362 14800

Transfer rate kcal/(h*m2*C) 191.3 162.1
Effective surface area m2 8.1 8.1
Corrected MTD C 9.87 11.22
Shell side temperature in/out C 64.9 39.97 64.9 40.89
Tube side temperature in/out C 35 40.23 35 40.04

Outlet temperature for pass C 1 36.75 36.61

2 37.96 37.75
3 38.82 38.59
4 39.44 39.21
5 39.9 39.69
6 40.23 40.04
7
8