DESIGN AND FABRICATION OF ONE

SHELL TWO PASS HEAT EXCHANGER

SESSION 2008 – 2012

SUBMITTED BY:

KALEEM ULLAH (UW-08-ME-002)

BILAL KHAN (UW-08-ME-003)

SAJID ALI (UW-08-ME-013)

SUPERVISOR:

MR.S.H SHAHID

WAH ENGINEERING COLLEGE

MECHANICAL ENGINEERING DEPARTMENT
 In the name of ALLAH, the most Gracious, most Compassionate

Recite with name of your Lord, Who created, He created man from the Clot
of blood,

Recite, for your Lord is most generous,

Who taught writing by the pen,

Taught man what he knew not!

Al-Quran
 UNDERTAKING
I certify that research work titled “DESIGN AND FABRICATION OF ONE SHELL TWO
PASS HEAT EXCHANGER” is our own work. The work has not been presented elsewhere
for assessment. Where material has been used from other sources it has been properly
acknowledged.

MECHANICAL ENGINEERING

Supervisor: Mr.SH Shahid

Signature:

Date:

Department of Mechanical Engineering

Wah Engineering College, University of Wah
WahCantt
 DESIGN AND FABRICATION OF ONE
SHELL TWO PASS HEAT EXCHANGER
 DEDIATED TO

“We dedicate our project to our

parents, teachers, and all those

who helped us by any means in

accomplishing this project and

achieving the required outcomes

 ACKNOWLEDEMENT

Initiating with the name of Almighty ALLAH, the Lord of Universe, who is the
entire source of all knowledge and wisdom endowed to mankind.

The authors wish to express their deepest thanks and gratitude to Mr.SH Shahid,
lecturer and their project advisor, for fruitful theoretical discussions, sharing his
practical experience and his interest in this project. He generously helped us in
the accomplishment of this report. His valuable suggestions, tricks and
techniques made the tedious task of completing this project much easier and on
scheduled time without which it would have been a far more arduous labor.

No words can describe our gratitude to our parents and their moral support and
prayers, who helped us to meet our targets.

Authors

KALEEM ULLAH
(UW-08-ME-BE-002)

BILAL KHAN
(UW-08-ME-BE-003)

MUHAMMAD SAJID ALI

(UW-08-ME-BE-002)
 PREFACE
Heat exchanger is important equipment used in industries such as
process industry, power, transportation, petroleum, air conditioning,
refrigeration, cryogenic, heat recovery, alternative fuel, and
manufacturing industries. This project was specially chosen for our
initial interest to work in process industry.
The thesis contains the basic knowledge of heat transfer, heat
exchanger, with special emphasis on the designing of one shell two
pass heat exchanger.

Authors
 TABLE OF CONTENTS
CHAPTER # 1
IDENTIFICATION OF PROBLEM ....... Error! Bookmark not defined.
1.1 Statement of Problem .......................... Error! Bookmark not defined.

CHAPTER # 2
LATEST THEORITICAL ASPECT ................................................... 17
INTRODUCTION ................................................................................. 17
2.1 Application ........................................... Error! Bookmark not defined.
2.2 Heat transfer process........................... Error! Bookmark not defined.
2.3 Fouling Factor ...................................... Error! Bookmark not defined.
2.3.1Analysis of heat exchanger................ Error! Bookmark not defined.
2.3.2Heat capicity rate ............................... Error! Bookmark not defined.
2.3.3 Selection of heat exchanger............. Error! Bookmark not defined.
2.3.3.1Heat transfer rate ........................... Error! Bookmark not defined.
2.3.3.2Cost................................................... Error! Bookmark not defined.
2.3.3.3Pumping power ............................... Error! Bookmark not defined.
2.3.3.4Size and weight................................ Error! Bookmark not defined.
2.3.3.5Type .................................................. Error! Bookmark not defined.
2.3.3.6Material ........................................... Error! Bookmark not defined.
2.3.3.7Othere considration ........................ Error! Bookmark not defined.
2.4 1-2 type heat exchanger ....................... Error! Bookmark not defined.
2.5.Basic components of 1-2 type heat exchanger....................................
2.5.1Tubes ................................................... Error! Bookmark not defined.
2.5.2Tube sheet ........................................... Error! Bookmark not defined.
2.5.3Shell and shell side nozzles ................ Error! Bookmark not defined.
2.5.4Channel covers .................................. Error! Bookmark not defined.
 2.5.5Pass Divider ........................................ Error! Bookmark not defined.
2.5.6Baffles.................................................. Error! Bookmark not defined.
2.6 TEMA shell and tube type heat exchanger designationError! Bookmark
not defined.

CHAPTER # 3
DESIGN OF 1-2 TYPE HEAT EXCHANGERError! Bookmark not defined.

CHAPTER # 4
DESIGN CALCULATIONS..................... Error! Bookmark not defined.
CHAPTER # 5

CHAPTER # 6

CHAPTER # 7
Autocad Drawings ................................................................................. 45

CHAPTER # 8
CONCLUSIONS .................................................................................... 50
7.1 Conclusions ....................................................................................... 51
REFRENCES ................................................................................... 52
 LIST OF FIGURES

Figure 2.1 Schematic representation of the ammonia synthesis processError! Bookmark not
defined.
Figure 2.2 Schematic representation of urea synthesis .....Error! Bookmark not defined.
Figure 2.3 Some chemicals of interest in urea production Error! Bookmark not defined.
Figure 3.1 DXU heat exchanger ........................................Error! Bookmark not defined.
Figure 3.2 Cross-sectional view of DXU ...........................Error! Bookmark not defined.
Figure 4.1 Design constraints ............................................Error! Bookmark not defined.
Figure 4.2 The design procedure for shell and tube heat exchanger Error! Bookmark not
defined.
Figure 4.3 Heat Transfer factor for cross flow tube banks Error! Bookmark not defined.
Figure 4.4 Tube row correction factor Fn ..........................Error! Bookmark not defined.
Figure 4.5 Window correction factor ................................Error! Bookmark not defined.
Figure 4.6 By pass correction factor .................................Error! Bookmark not defined.
Figure 4.7 Coefficient for Fl .heat transfer ........................Error! Bookmark not defined.
Figure 4.8 Friction factor for cross flow tube banks ..........Error! Bookmark not defined.
Figure 5.1 The 1-2 Heat exchangers ..................................Error! Bookmark not defined.
Figure 5.2 Temperature correction factor: one shell pass; two or more even tube 'passes
............................................................................................Error! Bookmark not defined.
Figure 5.3 Temperature correction factor: two shell passes; four or multiples of four tube
passes .................................................................................Error! Bookmark not defined.
Figure 5.4 Temperature correction factor: divided-flow shell; two or more even-tube passes
............................................................................................Error! Bookmark not defined.
Figure 5.5 Temperature correction factor, split flow shell, 2 tube passError! Bookmark not
defined.
Figure 5.6 Bundle dia clearance.........................................Error! Bookmark not defined.
Figure 5.7 Heat Transfer factor for cross flow tube banksError! Bookmark not defined.
Figure 5.8 Friction factor for cross flow tube banks ..........Error! Bookmark not defined.
Figure 5.9 Tube row correction factor Fn ..........................Error! Bookmark not defined.
Figure 5.10 Window correction factor ...............................Error! Bookmark not defined.
Figure 5.11 Coefficient for Fl .heat transfer .....................Error! Bookmark not defined.
Figure 5.12 By pass correction factor ................................Error! Bookmark not defined.
Figure 5.13 Coefficient for Fl’, pressure drop ...................Error! Bookmark not defined.
Figure 5.14 baffle geometrical factors ...............................Error! Bookmark not defined.
Figure 5.15 Bypass factor for pressure drop Fb ‘ ..............Error! Bookmark not defined.
Figure 6.1 slip-on nozzle flange........................................Error! Bookmark not defined.
Figure 6.2 : weld neck nozzle flange .................................Error! Bookmark not defined.
Figure 6.3 self-reinforced long weld neck nozzles ............Error! Bookmark not defined.
Figure 6.4 "swept" forged nozzles .....................................Error! Bookmark not defined.
Figure 6.5 Nozzle with liner ..............................................Error! Bookmark not defined.
Figure 6.6 standard roller expansion ..................................Error! Bookmark not defined.
Figure 6.7 roller expansion for bimetal..............................Error! Bookmark not defined.
Figure 6.8 explosive expansion.........................................Error! Bookmark not defined.
Figure 6.9 typical tube end welds. .....................................Error! Bookmark not defined.
Figure 6.10 explosive tube end welding. ...........................Error! Bookmark not defined.
Figure 6.11 back-bore end welding ...................................Error! Bookmark not defined.
Figure 6.12 thick-wall bellows. .........................................Error! Bookmark not defined.
Figure 6.13 thin-wall bellows ............................................Error! Bookmark not defined.
Figure 6.14 test flange and gland for floating-head exchangerError! Bookmark not defined.
Figure 6.15 hydrostatic testing of split-backing-ring floating-head exchanger ......... Error!
Bookmark not defined.
Figure 6.16 Ring-type flanges............................................Error! Bookmark not defined.
Figure 6.17 weld neck flange .............................................Error! Bookmark not defined.
Figure 6.18 6.18 clad flange ..............................................Error! Bookmark not defined.
Figure 6.19 lap-type flange ................................................Error! Bookmark not defined.
Figure 6.20 bolt extension sleeve.......................................Error! Bookmark not defined.
Figure 6.21 bolt with spring washers .................................Error! Bookmark not defined.
Figure 6.22 Types of flanges .............................................Error! Bookmark not defined.
Figure 6.23 bolt load and gasket reaction ..........................Error! Bookmark not defined.
Figure 6.24 forces and lever arms for integral flange in operating condition............ Error!
Bookmark not defined.
Figure 6.25 most common pass arrangements for multi pass channelError! Bookmark not
defined.
Figure 7.0.1 Stress in Cylinder ..........................................Error! Bookmark not defined.
Figure 0.2 Hoop Stress in Thin Cylinder ..........................Error! Bookmark not defined.
Figure 0.3 Longitudinal Stress in Thin Cylinder ..............Error! Bookmark not defined.
Figure 0.4 Butt joint ...........................................................Error! Bookmark not defined.
Figure 0.5 welding arrangement of the vessel ...................Error! Bookmark not defined.
Figure 0.6 Longitudinal joint with two cover plates ..........Error! Bookmark not defined.
Figure 0.7 thin sphere under internal pressure p ................Error! Bookmark not defined.

LIST OF TABLES

Table 2.1 Composition of the gas stream after each process step† . Error! Bookmark not
defined.
Table 2.2 Ammonia specifications ...................................Error! Bookmark not defined.
Table 2.3 Urea granule specifications ................................Error! Bookmark not defined.
Table 5.1 Heat Transfer Coefficients .................................Error! Bookmark not defined.
Table 5.2 Conductivity of metals .......................................Error! Bookmark not defined.
Table 5.3 Typical overall coefficients ...............................Error! Bookmark not defined.
Table 5.4 Typical pitch .....................................................Error! Bookmark not defined.
Table 5.5 Assumed & Calculated Overall Heat Transfer CoefficientError! Bookmark not
defined.
Table 5.6 Thermal Design Summary ................................Error! Bookmark not defined.
Table 6.1 Principal pressure vessel codes ........................................................................ 35
Table 6.2 Steel type selection at various temperature rangesError! Bookmark not defined.
Table 6.3 Description of plate materials ............................Error! Bookmark not defined.
Table 6.4 Bolting data ........................................................Error! Bookmark not defined.
Table0.1 Physical Properties of S.S 304 ...........................Error! Bookmark not defined.
Table 0.2 Mechanical Properties of S.S 304 ......................Error! Bookmark not defined.
Table 7.0.3 Boiler Code .....................................................Error! Bookmark not defined.
Table 7.4 Mechanical Design Summary ...........................Error! Bookmark not defined.
 Assumption

 The shell fluid temperature is an isothermal temperature at any cross-

section.
 There is equal amount of heating surface in each pass.
 The overall heat transfer coefficient is constant.
 The rate of flow of each fluid is constant.
 The specific heat of each fluid is constant.
 There are no phase changes involving evaporation or condensation in any
part of heat exchanger.
 Heat losses are negligible.
 The fluid properties such as temperature and velocity at inlet and outlet
remain the same.
 The kinetic and potential energy changes are negligible because there is is
little or no change in the velocity of fluid.
 Material of construction for shell is transparent.
 Material of construction for tube is stainless steel.
 Axial heat conduction along the tube is usually insignificant and can be
considered negligible.
 18BWG (Birmingham wire gauge) with mm tube pitch are used.
 According to TEMA standards Baffle spacing should not be less than 1/5
of(shell diameter),so Baffle spacing B = 90mm
 NOMENCLATURE OF THE TERMS USED IN
DESIGN
Baffle spacing B Tube pitch PT
 CHAPTER # 1

IDENTIFICATION OF PROBLEM OF
DESIGN PROJECT
PROJECT DEFINITION:

To Design and fabricate a 1 shell and 2 tubes pass heat exchanger. The basic
concept of this project has been taken from a heat exchanger of similar design
contained in the catalogue of TQ, the supplier of laboratory equipment for
technical teaching. Modification have been incorporated, wherever required,
to suit local material availability and fabrication limitation keeping in view
economical aspect.

THE PROJECT CONSISTS OF THE FOLLOWING MAIN ASPECT:

1. Design of shell and tube

2. Design economy and optimization
3. Design validation
4. Material selection
5. Fabrication and testing
 CHAPTER # 2

LATEST THEORITICAL ASPECT

INTRODUCTION
“Heat exchanger is a device that facilitates the exchange of heat between two fluids that are
at different temperature while keeping them from mixing with each other. “It differs from
mixing chamber that it does not allow to two fluids to mix they are separated by a wall

Or

A heat exchanger is a heat-transfer devise that is used for transfer of internal thermal energy
between two or more fluids available at different temperatures. In most heat exchangers, the
fluids are separated by a heat-transfer surface, and ideally they do not mix.
Common examples of heat exchangers familiar to us in day-to-day use are automobile
radiators, condensers, evaporators, air pre heaters, and oil coolers.

APPLICATION:
Heat exchangers are used in the following application.
1. Power plant
2. Petroleum
3. Heating, ventilating, refrigeration and air conditioning system (HVRAC)
4. Heat recovery system.
5. Chemical process industry.

TYPE OF HEAT EXCHANGERS

Different heat transfer applications require different types of hardware and different
configurations of heat transfer equipment. The attempt to match the heat transfer hardware to
the heat transfer requirements within the specified constraints has resulted in numerous types
of innovative heat exchanger designs.

DOUBLE-PIPE HEAT EXCHANGER

The simplest type of heat exchanger consists of two concentric pipes of different diameters,
as shown in Figure, called the double-pipe heat exchanger. in parallel flow, both the hot and
cold fluids enter the heat exchanger at the same end and move in the same direction. In
counter flow, on the other hand, the hot and cold fluids enter the heat exchanger at opposite
ends and flow in opposite directions.

COMPACT HEAT EXCHANGER

Another type of heat exchanger, which is specifically designed to realize a large heat transfer
surface area per unit volume, is the compact heat exchanger. The ratio of the heat transfer
surface area of a heat exchanger to its volume is called the area density. A heat exchanger
with 700 m2/m3 (or 200 ft2/ft3) is classified as being compact. Examples of compact heat
exchangers are car radiators (1000 m2/m3), glass ceramic gas turbine heat exchangers (6000
m2/m3), the regenerator of a Sterling engine (15,000 m2/m3), and the human lung (20,000
m2/m3). In compact heat exchangers, the two fluids usually move perpendicular to
each other, and such flow configuration is called cross-flow. The cross-flow is further
classified as unmixed and mixed flow, depending on the flow configuration, as shown in
Figure. In (a) the cross-flow is said to be unmixed since the plate fins force the fluid to flow
through a particular inter fin spacing and prevent it from moving in the transverse direction
(i.e., parallel to the tubes). The cross-flow in (b) is said to be mixed since the fluid now is free
to move in the transverse direction. Both fluids are unmixed in a car radiator. The presence of
mixing in the fluid can have a significant effect on the heat transfer characteristics of the heat
exchanger.
 A gas-to-liquid compact heat exchanger for a residential air conditioning system

REGENERATIVE HEAT EXCHANGER

Another type of heat exchanger that involves the alternate passage of the hot and cold fluid
streams through the same flow area is the regenerative heat exchanger. The static-type
regenerative heat exchanger is basically a porous mass that has a large heat storage capacity,
such as a ceramic wire mesh. Hot and cold fluids flow through this porous mass alternatively.
Heat is transferred from the hot fluid to the matrix of the regenerator during the flow of the
hot fluid, and from the matrix to the cold fluid during the flow of the cold fluid. Thus, the
matrix serves as a temporary heat storage medium. The dynamic-type regenerator involves a
rotating drum and continuous flow of the hot and cold fluid through different portions of the
drum so that any portion of the drum passes periodically through the hot stream, storing heat,
and then through the cold stream, rejecting this stored heat. Again the drum serves as the
medium to transport the heat from the hot to the cold fluid stream.
SHELL AND-TUBE HEAT EXCHANGERS
The most common type of heat exchanger in industrial applications is the shell-and-tube heat
exchanger, shown in Figure. Shell-and-tube heat exchangers contain a large number of tubes
(sometimes several hundred) packed in a shell with their axes parallel to that of the shell.
Heat transfer takes place as one fluid flows inside the tubes while the other fluid flows
outside the tubes through the shell. Baffles are commonly placed in the shell to force the
shell-side fluid to flow across the shell to enhance heat transfer and to maintain uniform
spacing between the tubes. Despite their widespread use, shell and- tube heat exchangers are
not suitable for use in automotive and aircraft applications because of their relatively large
size and weight. Note that the tubes in a shell-and-tube heat exchanger open to some large
flow areas called headers at both ends of the shell, where the tube-side fluid accumulates
before entering the tubes and after leaving them. Shell-and-tube heat exchangers are further
classified according to the number of shell and tube passes involved. Heat exchangers in
which all the tubes make one U-turn in the shell, for example, are called one-shell-pass and
two tube- passes heat exchangers. Likewise, a heat exchanger that involves two passes in the
shell and four passes in the tubes is called a two-shell-passes and four-tube-passes heat
exchanger.
 (one-shell pass and one-tube pass)

1 SHELL 2 PASS HEAT EXCHANGER

HEAT TRANSFER PROCESS

Heat exchanger includes two flowing fluids separated by wall.

1. Heat first transmitted from fluid to wall by convection.

2. Through the wall by conduction.
3. From the wall to cold fluid by convection.
The total thermal resistance associated with heat transfer process involves two convection
resistance and one conduction resistances shown in the above figure. so the total thermal
resistance become

1 ln(𝐷𝑜 ⁄𝐷𝑖 )
𝑅 = ℎ 𝐴 + 2𝜋𝑘𝐿 + ℎ𝑜1𝐴𝑜 ; Where
𝑖 𝑖

𝐴𝑂 = surface area of outer surface of the wall

𝐴𝑖 = surface area of inner surface of the wall

So the heat transfer through the pipe is

𝑻𝑨 − 𝑻𝑩
𝒒 = 𝟏 𝐥𝐧(𝑫𝒐 ⁄𝑫𝒊 ) 𝟏
+ +
𝒉𝒊 𝑨𝒊 𝟐𝝅𝒌𝑳 𝒉𝒐 𝑨𝒐
In the analysis of heat exchangers, it is convenient to combine all the thermal resistances in the path of heat
flow from the hot fluid to the cold one into a single resistance R, and to express the rate of heat transfer
between the two fluids as

∆𝑇
𝑄= = 𝑈𝐴∆𝑇 = 𝑈𝑖 𝐴𝑖 ∆𝑇 = 𝑈° 𝐴° ∆𝑇
𝑅
where U is the overall heat transfer coefficient, whose unit is W/m2 · °C, which is identical to
the unit of the ordinary convection coefficient h. Canceling ∆T, Equation reduces to

1 1 1 1 1
= = =𝑅= + 𝑅𝑤𝑎𝑙𝑙 +
𝑈𝐴𝑆 𝑈𝑖 𝐴𝑖 𝑈° 𝐴° ℎ𝑖 𝐴𝑖 ℎ° 𝐴°

Representative values of overall heat transfer coefficient in heat exchanger

Type of heat exchanger Units U, (𝑊 ⁄ 𝑚2 . ℃)

Water to water 850-1700
Water to oil 100-350
Water to gasoline or kerosene 300-1000
Feed water heater 1000-8500
Steam to light fuel oil 200-400
Steam condenser 1000-600
Freon condenser(water cooled) 300-1000
Ammonia condenser(water cooled) 800-1400
Alcohol condenser(water cooled) 250-700
Gas to gas 10-40
Water to air finned tubes(water in tubes) 30-60
400-850
Steam to air in finned tubes(steam in tubes) 30-300
400-4000

FOULING FACTOR
After a period of operation the heat-transfer surfaces for a heat exchanger may become coated
with various deposits present in the flow systems ,or surfaces may become corroded as a
result of the interactions between the fluids and the material used for construction of the heat
exchanger. in either event, this coating represents an additional resistance to the heat flow,
and thus result in decreased performance. The overall effect is usually represented by a
fouling factor, or fouling resistance, Rf. which must be included along other thermal
resistances making up the overall heat-transfer coefficient.

The most common type of fouling is the precipitation of solid deposits in a fluid on the heat
transfer surfaces. Another form of fouling, which is common in the chemical process
industry, is corrosion and other chemical fouling. In this case, the surfaces are fouled by the
accumulation of the products of chemical reactions on the surfaces. This form of fouling can
be avoided by coating metal pipes with glass or using plastic pipes instead of metal ones.
Heat exchangers may also be fouled by the growth of algae in warm fluids. This type of
fouling is called biological fouling and can be prevented by chemical treatment.
The fouling factor is obviously zero for a new heat exchanger and increases with time as the
solid deposits build up on the heat exchanger surface. The fouling factor depends on the
operating temperature and the velocity of the fluids, as well as the length of service. Fouling
increases with increasing temperature and decreasing velocity. The overall heat transfer
coefficient relation given above is valid for clean surfaces and needs to be modified to
account for the effects of fouling on both the inner and the outer surfaces of the tube. For an
unfinned shell-and-tube heat exchanger, it can be expressed as

1 1 1 1 𝑅𝑓𝐼 ln(𝐷𝑜 ⁄𝐷𝑖 ) 𝑅𝑓° 1

= = = 𝑅= + + + +
𝑈𝐴𝑆 𝑈𝑖 𝐴𝑖 𝑈° 𝐴° ℎ𝑖 𝐴𝑖 𝐴𝐼 2𝜋𝑘𝐿 𝐴𝐼 ℎ° 𝐴°

(Source: tabular exchange manufacturing association 7th edition)

2
Fluid 𝑅𝑓 , ( 𝑚 . ℃⁄𝑊 )
Distilled water, sea water, river water, boiler feed water
TEMPRATURE
Below 50c 0.0001
Above 50c 0.0002
Fuel oil 0,0009
Steam(oil free) 0.0001
Refrigerants(liquid) 0.0002
Refrigerants(vapor) 0.0004
Alcohol vapor 0.0001
air 0.0004

Fouling can be reduced by:

• keeping velocities sufficiently high to avoid deposits

• avoiding stagnant regions where dirt will collect

• avoiding hot spots where coking or scaling might occur

• avoiding cold spots where liquids might freeze or where corrosive products may
condense for gases

SELECTION OF HEAT EXCHANGER

The heat exchanger selection depend upon many factor in which some are:

HEAT TRANSFER RATE

This is the most important quantity in the selection of a heat exchanger. A heat exchanger
should be capable of transferring heat at the specified rate in order to achieve the desired
temperature change of the fluid at the specified mass flow rate.

COST
Budgetary limitations usually play an important role in the selection of heat exchangers,
except for some specialized cases where “money is no object.” An off-the-shelf heat
exchanger has a definite cost advantage over those made to order. However, in some cases,
none of the existing heat exchangers will do, and it may be necessary to undertake the
expensive and time-consuming task of designing and manufacturing a heat exchanger from
scratch to suit the needs. This is often the case when the heat exchanger is an integral part of
the overall device to be manufactured. The operation and maintenance costs of the heat
exchanger are also important considerations in assessing the overall cost.
PUMPING POWER
In a heat exchanger, both fluids are usually forced to flow by pumps or fans that consume
electrical power. The annual cost of electricity associated with the operation of the pumps
and fans can be determined from

Operating cost _ (Pumping power, kW) _ (Hours of operation, h)

_ (Price of electricity, $/kWh)

where the pumping power is the total electrical power consumed by the motors of the pumps
and fans. For example, a heat exchanger that involves a 1-hp pump and a -hp fan (1 hp _
0.746 kW) operating 8 h a day and 5 days a week will consume 2017 kWh of electricity per
year, which will cost $161.4 at an electricity cost of 8 cents/kWh. Minimizing the pressure
drop and the mass flow rate of the fluids will minimize the operating cost of the heat
exchanger, but it will maximize the size of the heat exchanger and thus the initial cost. As a
rule of thumb, doubling the mass flow rate will reduce the initial cost by half but will increase
the pumping power requirements by a factor of roughly eight. Typically, fluid velocities
encountered in heat exchangers range between 0.7 and 7 m/s for liquids and between 3 and
30 m/s for gases. Low velocities are helpful in avoiding erosion, tube vibrations, and noise as
well as pressure drop.

SIZE AND WEIGHT

Normally, the smaller and the lighter the heat exchanger, the better it is. This is especially the
case in the automotive and aerospace industries, where size and weight requirements are most
stringent. Also, a larger heat exchanger normally carries a higher price tag. The space
available for the heat exchanger in some cases limits the length of the tubes that can be used.

TYPE
The type of heat exchanger to be selected depends primarily on the type of fluids involved,
the size and weight limitations, and the presence of any phase change processes. For
example, a heat exchanger is suitable to cool a liquid by a gas if the surface area on the gas
side is many times that on the liquid side. On the other hand, a plate or shell-and-tube heat
exchanger is very suitable for cooling a liquid by another liquid

MATERIAL
The materials used in the construction of the heat exchanger may be an important
consideration in the selection of heat exchangers. For example, the thermal and structural
stress effects need not be considered at pressures below 15 atm or temperatures below 150°C.
But these effects are major considerations above 70 atm or 550°C and seriously limit the
acceptable materials of the heat exchanger. A temperature difference of 50°C or more
between the tubes and the shell will probably pose differential thermal expansion problems
and needs to be considered. In the case of corrosive fluids, we may have to select expensive
corrosion-resistant materials such as stainless steel or even titanium if we are not willing to
replace low-cost heat exchangers frequently

BASIC COMPONENET
It is essential for the designer to have a good working knowledge of the mechanical features
of STHEs and how they influence thermal design. The principal components of an STHE are:
• Shell
• shell cover
• Tubes;
• Channel
• channel cover
• Tube sheet

TUBE
The tubes are the basic component of the shell and tube heat exchanger, providing the heat
transfer surface between one fluid flowing inside the tube and other fluid flowing across the
outside of the tubes. The tube may be seamless or welded and most commonly made of
copper or steel alloys. Other alloys of nickel, titanium, or aluminum may also be used for
specific applications.

The tube may be either bare or extended surface on the outside. Extended or enhanced
surface tube s are used when one fluid has a substantially lower heat transfer coefficient then
the other fluid .doubly enhanced tubes that is , with enhancement both inside and outside are
available that can reduce the size and cost of the exchanger. Extended surfaces (finned tubes)
provide two to four times as much heat transfer area on the outside as the corresponding bare
tube, and this area helps to offset a lower outside heat transfer coefficient.

Tubes should be able to withstand the following

1. Operating temperature and pressure on both sides

2. Thermal stresses due to the differential thermal expansion between the shell and the tube
bundle
3. Corrosive nature of both the shell-side and the tube-side fluids
There are two types of tubes: straight tubes and U-tubes. The tubes are further classified as
1. Plain tubes
2. Finned tubes
3. Duplex or bimetallic tubes
4. Enhanced surface tubes
TUBE SHEET
Depending on the service, and metal required, tube sheets, less than about 100 mm thick are
made from plate, but at greater thicknesses or for high-integrity services, they are made from
forged disks. When tube sheets in other than carbon or low-alloy steels are required, the use
of clad plate should be considered. This may provide a cost saving, particularly at the larger
diameters aid thicknesses.
A clad tube sheet will consist of a carbon or low-alloy steel backing plate, having a thickness
suitable for the design temperature and pressure, with a layer of the required tube sheet metal
bonded to it. The cladding will be about 9.5 and 3 mm thick for multi-and single tube-side
passes, respectively. Although the clad metal may be applied by weld deposition, explosion-
clad tube sheets are widely used because the process provides a high-integrity bond with no
contamination of the cladding from the backing metal. In addition, the explosion-clad process
provides a much greater combination of cladding/backing metals than the weld deposition
process.
The use of clad tube sheets becomes essential when a single metal that is corrosion resistant
to both shell- and tube-side fluids is not available or is too costly. TEMA specifies tolerances
for tube whole diameter, ligament width, and drill drift. Hole diameter tolerances provide for
"standard fit" and "special close fit" of the tubes, the latter fit being recommended for tubes
that are susceptible to work hardening. Holes are drilled, reamed, and the edges chamfered
slightly to prevent damage during bundle assembly. Each pair of tube sheets of double tube
sheet exchangers should be drilled together, or one jig drilled from the other, and held
together as a matching pair throughout all stages of manufacture.
Minimum tube sheet thicknesses are provided by TEMA, and for class R the total thickness
less corrosion allowance should not be less than the tube outside diameter. Some fabricators
may standardize on greater minimum thicknesses in order to reduce distortion during tube
end attachment

CHANNEL COVER

SHELL
The shell barrel must be straight and have no out-of-roundness, as a tightly fitting tube bundle
must be inserted in it. Most shell and head barrels greater than about 450 mm in inside
diameter are rolled from plate, and a complete shell barrel may comprise several smaller
barrels, or strakes, welded together end to end. If there is any out-of-roundness, individual
strakes are rerolled after welding the longitudinal seams. The longitudinal seams of adjoining
strakes are always staggered. The inside diameter of a rolled shell should not exceed the
design inside diameter by more than 3.2 mm (1/8 in) as determined by circumferential
measurement. All internal welds must be made flush.
When welding large nozzles to the shell "shrinkage" may occur at the nozzle/shell junction
and effective measures, such as the use of temporary stiffening, must be taken to avoid it.
Shrinkage reduces the shell diameter at the nozzle/shell junction so that the baffle diameter
must be reduced accordingly. The increased clearance between baffle and shell may result in
reduced thermal performance.
Standard pipe less than 450 mm in diameter is usually available, and this will be used for the
shell and head barrels instead of rolled plate. Depending on the fabricators roll capacity, at
thicknesses of the order of 80 mm and greater or large thickness/diameter ratios, it may be
necessary to use forged instead of rolled barrels.
When an expensive barrel metal is required for corrosion resistance purposes only, the barrel
is formed from the selected metal if its thickness is less than about 15 mm. Above this the use
of clad metal should be investigated, as it may provide a cost saving. The clad metal will
usually comprise a steel plate, having a thickness suitable for the pressure and temperature
conditions with a layer of the required corrosion resistant metal, about 3 mm thick, bonded to
it. The cladding may be applied by explosive, roll bonding, or weld deposition methods.
TEMA specifies minimum shell and head barrel thicknesses, which depend on barrel
diameter, metal and TEMA class.

SHELL AND SHELL SIDE NOZZLE

TUBE-SIDE CHANNEL AND NOZZLE

BAFFLE
Baffles are used to support tubes, enable a desirable velocity to be maintained for the shell
side fluid, and prevent failure of tubes due to flow-induced vibration. There are two types of
baffles:
 plate
 rod
Plate baffles may be single-segmental, double-segmental, or triple-segmental, as shown in
Figure.

The Baffle spacing is the centerline-to-centerline distance between adjacent baffles. It is the
most vital parameter in STHE design. The TEMA standards specify the minimum baffle
spacing as one-fifth of the shell inside diameter or 2 in., whichever is greater. Closer spacing
will result in poor bundle penetration by the shell side fluid and difficulty in mechanically
cleaning the outsides of the tubes. Furthermore, a low baffle spacing results in a poor stream
distribution as will be explained later.

ANALYSIS OF HEAT EXCHANGER

Heat exchangers are commonly used in practice, and an engineer often finds himself in a
position to select a heat exchanger that will achieve a specified temperature change in a fluid
stream of known mass flow rate, or to predict the outlet temperatures of the hot and cold fluid
streams in a specified heat exchanger. In upcoming sections, we will discuss the two methods
used in the analysis of heat exchangers. Of these, the log mean temperature difference (or
LMTD) method is best suited for the first task and the effectiveness–NTU method for
the second task as just stated. But first we present some general considerations
Heat exchangers usually operate for long periods of time with no change in their operating
conditions. Therefore, they can be modeled as steady-flow devices. As such,
 The mass flow rate of each fluid remains constant,
 The fluid properties such as temperature and velocity at any inlet or outlet remain the
same.
 The fluid streams experience little or no change in their velocities and elevations, and
thus the kinetic and potential energy changes are negligible.
 The specific heat of a fluid, in general, changes with temperature. But, in a specified
temperature range, it can be treated as a constant at some average value with little loss
in accuracy.
 Axial heat conduction along the tube is usually insignificant and can be considered
negligible.
 The outer surface of the heat exchanger is assumed to be perfectly insulated, so that
there is no heat loss to the surrounding medium, and any heat transfer occurs between
the two fluids only.
Under these assumptions, the first law of thermodynamics requires that the rate of heat
transfer from the hot fluid be equal to the rate of heat transfer to the cold one. That is,

𝑄 = 𝑚𝑐° 𝐶𝑝𝑐 (𝑇𝐶,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )

𝑄 = 𝑚ℎ° 𝐶𝑝ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 )

where the subscripts c and h stand for cold and hot fluids, respectively, and

𝑚𝑐° = 𝑚ℎ° = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

𝐶𝑝𝑐 = 𝐶𝑝ℎ = 𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 ℎ𝑒𝑎𝑡𝑠

𝑇𝐶,𝑜𝑢𝑡 = 𝑇ℎ,𝑜𝑢𝑡 =outlet temperatures

𝑇𝑐,𝑖𝑛 = 𝑇ℎ,𝑖𝑛 = 𝑖𝑛𝑙𝑒𝑡 𝑡𝑒𝑚𝑝𝑟𝑎𝑡𝑢𝑟𝑒

In heat exchanger analysis, it is often convenient to combine the product of the mass flow
rate and the specific heat of a fluid into a single quantity. This quantity is called the heat
capacity rate and is defined for the hot and cold fluid streams as

𝐶𝒉 = 𝒎°𝒉
 MECHANICAL DESIGN NOMENCLATURE

SCOPE OF MECHANICAL DESIGN

A designer must know how to apply certain codes and standards, which are available for
heat exchanger. In mechanical designing of heat exchanger, first of all the designer decides
the type of heat exchanger. Following are the important points, which should be kept in mind
while doing mechanical design of heat exchanger.

 To calculate shell thickness against design pressure.

 To check the thickness of tube against design pressure.
 To calculate the channel thickness that is of both front and rear ends.
 Flange calculations.
 Tube sheet calculations.
 To design and calculate the thickness and dia of baffles.
  To calculate number of tie-rods and dia of tie-rods.
 To calculate the number of spacers, dia and length of spacer.
 To calculate the size and thickness of partition plates.
 Location of Impingement plate.
 To design and calculate size and thickness of inlet and outlet nozzles.
 To select and calculate the size of gasket.
 Calculation of Hard-Ware items that is bolts, Nuts, washer etc.
 Material selection.

MECHANICAL DESIGN CODES

Introduction

Pressure vessel codes, which also cover the mechanical design of shell and tube
exchangers, fulfill various functions; in several countries a national code is legally enforced,
and compliance with the code is mandatory for items supplied to that country, whether built
there or imported. Table 6.1 shows the status of the principal codes covering exchanger
design. Where no code is shown for a country, the table shows the codes generally accepted.
The requirements of U.S., U.K., and German codes, as they affect shell-and-tube exchangers,
are listed. The codes aim to achieve safe construction and give rules for design and
fabrication, which are based on experience with conventional plant. However, when the
components differ from conventional design or are outside the range of the code rules, or
when more certain assurance of safety is required, it may be necessary to justify the design
using alternative codes or a stress analysis or component testing. These alternatives must be
agreeable to the purchaser and the inspecting authority.

Codes also provide a useful tool for the education of junior engineers or those entering the
vessel and exchanger field, and this aspect should not be overlooked when new codes or rules
are being formulated. As well as giving rules for design and fabrication, most codes are
specific as to acceptable materials, but usually the range of materials is wide enough to allow
the designer a choice.

Once the designer has made a choice of material, the design code gives an allowable design
stress that is used to dimension the pressurized components, and the code specifies any
special fabrication requirements for that material, such as heat treatment, for example.
Although codes do list acceptable materials, they also permit other materials.
ASME VIII
The listed materials are taken from specifications of the ASTM. In order to use other
materials for ASME-coded vessels, special application must be made to, and approval
secured from, the ASME Code Committee.

Table 0.1 Principal pressure vessel codes

BS 5500
Materials other than those listed in the code may be used by agreement between
purchaser and manufacturer provided that they are covered by a written specification as
comprehensive as the BS specification for the equivalent material and that, the design stresses
are determined in a manner consistent to BS.
A. D. Merkblatter
The A. D. Merkblatter W series of specifications lists acceptable materials, but others
may be authorized with the agreement of the inspecting authority. In the latter case the W
specifications give requirements that must be satisfied.

ASME Boiler and Pressure Vessel Code Section VIII, Div. 1

This code gives minimum requirements for the design, fabrication, inspections and
certification of vessels with design pressures between 1.03 bar g (15 psig) and 206 bar (3000
psig). Where the design needs to be justified by a full stress analysis, Div. 2 of this code
should be used. New editions of the code are usually issued every 3 year, but interim
revisions are made twice yearly in the form of addenda. The ASME code references used
refer to the 1977 edition.

TEMA: (Standards of Tubular Exchanger Manufacturers Association)

These standards serve to supplement and define the ASME Pressure Vessel Code for
all shell-and-tube exchanger applications (double-pipe exchangers are not included).
Although TEMA is linked specifically to ASME VIII, it is a useful standard that can be used
to supplement other national codes. Recommendations for construction are given in three
classes, the class being specified by the purchaser. The design rules for each class are the
same, the only difference being in dimensions and details of construction.
Class R is for the generally severe requirements of petroleum and related processing
applications. Class C is for the generally moderate requirements of commercial and general
process service. Class B is for chemical process service.
The numbering system is common to all classes, and the TEMA references used refer to class
R, C, or B of the 1978 edition. This edition carries for the first time a section entitled
"Recommended Good Practice" relating to aspects not covered in the main sections of the
standard, particularly the requirements for exchangers with shell diameters from 1524 to
2540 mm (60 to 100 in). The numbering system used is the same as in the three main sections
of TEMA, and an * is used throughout to denote that there is an additional recommended
good practice.

BS 5500: The British Standard Specification for Unfired Fusion-Welded Pressure Vessels
This recently introduced code (41 replaces BS 1500 and 351515 and is intended to
unify the U.K. requirements for all pressure vessels. A major departure for this code is that
the purchaser now specifies the construction category (BS 5500 3.4), which then defines the
amount of non-destructive testing and restricts the permitted materials. The degree of testing
is not now reflected by the use of design stress-reduction factors. The code references used in
Sec. 6.3 refer to the third issue of BS 5500.

A.D. Merkblatter: German Pressure Vessel Regulations

These regulations are in the form of data sheets covering different aspects of vessel
design and construction, and are produced by a group of associations. Revisions are made
from time to time to keep up with advances in the knowledge. Some aspects of vessel and
exchanger design are not covered, and the method is agreed upon by the purchaser, inspecting
authority, and designer. The code references used refer to the 1977 edition of A. D.
Merkblatter.
International codes
The International Standards Organization (ISO) has been endeavoring for some time
to write an international code for pressure vessels. Various working groups have written draft
sections of the code, and these were submitted in late 1973 to form a proposed draft standard
DIS 2694, this draft was considered by the subscribing countries to ISO, but when votes were
cast in 1974 many major countries voted against its acceptance. The draft was then sent back
to the organizing secretariat and working groups with comments, but there has been no action
to date.
In Europe, the EEC has published a Council Directive of July 27, 1976, giving a
general framework to common provisions for vessels and methods of inspecting them. The
intention is that separate directives for different categories of vessels will lay down the
technical requirements for design and methods of inspection, and thus will achieve free
movement of vessels within the EEC and avoid multiple inspections.
European standards will be organized by CEN (Comite European de Normalisation),
and a draft for "simple" pressure vessels has been written. Unfired pressure vessels are being
considered by CEN working group 54, but the EEC Directive is awaited.

TEMA DESIGNATIONS FOR SHELL-AND-TUBE HEAT

EXCHANGERS
DESIGN AND FABRICATION OF ONE
SHELL TWO PASS HEAT EXCHANGER

3.1 How to design a shell and tube heat exchanger

3.1.1 size

3.2 effective design shell and tube heat exchanger

BAFFLES:

Baffles must generally be employed on the shell-side to support the tubes, to maintain the
tube spacing, and to direct the shell-side fluid across or along the tube bundle in a specified
manner. There are a number of different types of baffles and these may be installed in
different ways to provide the flow pattern required for a given application
Classification of Baffles
Baffles are either normal or parallel to the tubes. Accordingly, baffles may be classified as
transverse or longitudinal. The transverse baffles direct the shell-side fluid into the tube
bundle at approximately right angles to the tubes, and increase the turbulence of the shell
fluid. Every shell and tube exchanger has transverse baffles except the X and K shells, which
have only support plates. The longitudinal baffles are used to control the direction of the shell
side flow. For example, F, G , and H shells have longitudinal baffles. In the F shell, an overall
counter flow is achieved.

Transverse Baffles
Transverse baffles are of two types:
(1) Plate baffles: Three types of plate baffles are
(1) Segmental,
(2) Disk and doughnut
(3) Orifice baffles
(2) Rod baffles.

. Segmental Baffles
The segmental baffle is a circular disk (with baffle holes) having a segment removed.
Predominantly,
a large number of shell and tube exchangers employ segmental baffles. This cutting is
denoted as the baffle cut and it is commonly expressed as a percentage of the shell inside
diameter. Here the percent baffle cut is the height, H, given as a percentage of the shell inside
diameter, D,. The segmental baffle is also referred to as a single segmental baffle. The heat
transfer and pressure drop of cross flow bundles are greatly affected by the Baffle cut. The
baffle cuts vary from 20 to 49% with the most common being 20-25%, and the optimum
baffle cut is generally 20%, as it affords the highest heat transfer for a given Pressure drop.
Baffle cuts smaller than 20% can result in high pressure drop. As the baffle cut increases
beyond 20%, the flow pattern deviates more and more from cross flow and can result in
stagnant regions or areas with lower flow velocities; both of these reduce the thermal
effectiveness of the bundle

Baffle Spacing.
The practical range of single-segmental baffle spacing is to 1 shell diameter
, though optimum could be 40-50% . TEMA Table RCB-4.52 [3] provides maximum
baffle spacing for various tube outer diameters, tube materials, and the corresponding
maximum
allowable temperature limit. The baffles are generally spaced between the nozzles. The
inlet and outlet baffle spacings are in general larger than the “central” baffle spacing to
accommodate
the nozzles, since the nozzle dimensions frequently require that the nozzle should be
located far enough from the tube sheets.