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Heat Exchanger
Abstract
The objective of this experiment is to study the function and the working of
shell and tube heat exchanger. Calculations on the heat transfer and heat loss
were carried out for energy balance study. LMTD and heat transfer coefficient
also calculated for this experiment. From the data collected, we found out that
configuration of Shell and Tube heat exchanger has a higher effectiveness than
the co-current flow.

Definitions
Heat exchanger configurations are defined by the numbers and letters
established by the Tubular Exchanger Manufacturers Association (TEMA).
Refer to (TEMA )for full details.

For example: A heat exchanger with a single pass shell and multi-pass tube is
defined as a 1-2 unit. For a fixed tubesheet exchanger with removable channel
and cover, bonnet type rear head, one-pass shell 591mm (231/4in) inside
diameter with 4.9m(16ft) tubes is defined SIZE 23-192 TYPE AEL
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Introduction
A heat exchanger is an equipment in which heat exchange takes place bet
ween hot exhaust gas and cooled fluids that enter and exit at different
temperatures. The main function of heat exchanger is to either remove heat
from a hot gas or to add heat to the cold fluid. The direction of fluid motion
inside the heat exchanger can normally categorised as parallel flow. In this
experiment, we study only the parallel flow . For parallel flow, also known as
co-current flow, both the hot gas and cold fluids flow in the opposite direction.
The hot gas enter and cooled fluid enter the heat exchanger on the two opposite
ends and hot gas exit and cooled fluid exit the heat exchanger on the two
opposite ends. Both the fluids and gas enter and exit the heat exchanger on the
opposite ends. In this experiment, we focused on the shell and tube heat
exchanger.

Designing a heat exchanger usually involves three following steps:

1-Thermal design
2- Mechanical Design
3 - Manufacturing Design

Thermal design briefly includes calculation of the thermal transfer surface

for a certain flow and specific corrosion specifications, thermal expansion and
thermal pressure are considered. Applying physical characteristics and fluid
flow in converter manufacturing design - that includes minimum or optimum
cost - selecting appropriate material, sealing, determining converter internal
equipment and the optimum of arrangement of tubes and shells are of the cases
considered in Manufacturing Design [1]. This paper includes the special
attention to selecting the most appropriate material for producing tubes and
tubes sheets.
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Design Procedure and Calculation:

Design Guidelines

References: Hewitt et al “Process Heat Transfer” p267, Kern “Process

Heat Transfer” Chapter 7, p127 and Perry Section 11 p11-0 to p11-19
The Heat Exchanger Design Procedure using the LMTD:

• The procedure to be followed by the selection process is:

1. Select the type of heat exchanger suitable for the Application
2. Determine any unknown inlet or outlet temperature and the heat transfer
rate using an energy balance.
3. Calculate the log mean temperature difference Tlm and
the correction factor F,if necessary.
4. Obtain the value of the overall heat transfer co-efficient U.
5. Calculate the heat transfer surface areas need to meet requirements.
Shell side design

The shell side calculations are far more complex than those for the tube side.
This is mainly because on the shell side there is not just one flow stream but four
leakage or bypass streams. There are various shell side tube layout patterns and
baffling designs, which together determine the shell side stream analysis.
Shell configuration
TEMA defines various shell patterns based on the flow of the shell side fluid
through the shell (see Figure 1).
In a TEMA E single-pass shell, the shell side fluid enters the shell at one end
and leaves from the other end. This is the most common shell type more heat
exchangers are built to this configuration than all other configurations combined.
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Shell Diameter
The design process is to fit the number of tubes into a suitable shell to
achieve the desired shell side velocity 4ft/s(1.219m/s) subject to pressure drop
constraints. Most efficient conditions for heat transfer is to have the maximum
number of tubes possible in the shell to maximize turbulence.
Preferred tube length to shell diameter ratio is in the range 5 to 10.
Tube count data are given in Perry Table 11-3 where the following criteria have
been used
1) Tubes have been eliminated to provide entrance area for a nozzle equal to 0.2
times shell diameter
2) Tube layouts are symmetrical about both the horizontal and vertical axes
3) Distance from tube od to centerline of pass partition 7.9mm( 5/16 ) for shell id
<559mm (22in) and 9.5mm (3/8) for larger shells.
Shell Side Heat Transfer Coefficient :
 There are three rating methods to calculate the shell side heat
transfer coefficient:
 Kern method is a simplified approach suitable for shell side flow
without baffles
 Taborek method
 Bell Delaware method is the most complex but accurate way of rating a
heat exchanger with baffles
Heat Transfer Area
Using the maximum number of tubes, subject to adequate provision for inlet
nozzle, for a given shell size will ensure optimum shell side heat transfer in
minimizing tube bundle bypassing. The heat transfer area required design margin
is then achieved by adjusting the tube length subject to economic considerations.
On low cost tube materials it may be more economical to use standard lengths
and accept the increased design margin.
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It is a common practice to reduce the number of tubes to below the maximum

allowed particularly with expensive tube material. In these situations the
mechanical design must ensure suitable provision of rods, bar baffles, spacers,
baffles to minimize bypassing and to ensure mechanical strength.
Tube Passes
 A pass is when liquid flows all the way across from one end to the
other of the exchanger. We will count shell passes and tube passes.

 An exchanger with one shell pass and two tube passes is a 1-2
exchanger. Almost always, the tube passes will be in multiples of
two (1-2, 1-4, 2-4, etc.)

 Odd numbers of tube passes have more complicated mechanical

stresses, etc. An exception: 1-1 exchangers are sometimes used for
vaporizers and condensers.

 A large number of tube passes are used to increase the tube side
fluid velocity and heat transfer coefficient and minimize fouling.

 This can only be done when there is enough pumping power since
the increased velocity and additional turns increases the pressure
drop significantly.

 The number of tube passes depends on the available pressure drop.

 Higher velocities in the tube result in higher heat transfer

coefficients, at the expense of increased pressure drop.

 Therefore, if a higher pressure drop is acceptable, it is desirable to

have fewer but longer tubes (reduced flow area and increased flow
Length).

 Long tubes are accommodated in a short shell exchanger by

multiple tube passes.

 The number of tube passes in a shell generally range from 1 to 10

 The standard design has one, two, or four tube passes.

 An odd number of passes is uncommon and may result in

mechanical and thermal problems in fabrication and operation.
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Tube Materials

 Materials selection and compatibility between construction

materials and working fluids are important issues, in particular with
regard to corrosion and/or operation at elevated temperatures.

 Requirement for low cost, light weight, high conductivity, and good
joining characteristics often leads to the selection of Miled steel for
the heat transfer surface.

 On the other side, stainless steel is used for food processing or

fluids that require corrosion resistance.

 In general, one of the selection criteria for exchanger material

depends on the corrosiveness of the working fluid.

 A summary Table is provided as a reference for corrosive and

noncorrosive environments
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Materials for Corrosive & Noncorrosive Service :

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Tube Outside Diameter :

The most common sizes used are 3/4"od and 1"od Use smallest diameter
for greater heat transfer area with a normal minimum of 3/4"od tube due to
cleaning considerations and vibration.1/2"od tubes can be used on shorter tube
lengths say < 4ft. The wall thickness is defined by the Birmingham wire gage
(BWG) details are given in Appendix XI(Kern Table 10)

The most common plain tube sizes have 15.88,19.05, and 25.40 mm
(5/8, ¾, 1 inche) tube outside diameters.

From the heat transfer viewpoint, smaller-diameter tubes yield

higher heat transfer coefficients and result in a more compact exchanger.

However, larger-diameter tubes are easier to clean and more rugged.

The foregoing common sizes represent a compromise.

 For mechanical cleaning, the smallest practical size is 19.05 mm.

 For chemical cleaning, smaller sizes can be used provided that the
tubes never plug completely.

Tube Wall Thickness :

 The wall thickness of heat exchanger tubes is standardized in terms
of Birmingham Wire Gage BWG of the tube.
 Small tube diameters (8 to 15mm) are preferred for greater area to
volume density but are limited for the purposes of cleaning.
 Large tube diameters are often required for condensers and boilers.
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Tube layout patterns

There are four tube layout patterns, as shown in Figure 6: triangular
(30°), rotated triangular (60°), square(90°), and rotated square (45°).
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 The 90° layout will have the lowest heat transfer coefficient and
the lowest pressure drop.
 The square pitch (90° or 45°) is used when jet or mechanical
cleaning is necessary on the shell side. In that case, a minimum cleaning lane of
¼ in. (6.35 mm) is provided.

 The square pitch is generally not used in the fixed header sheet design
because cleaning is not feasible.

A triangular (or rotated triangular) pattern will accommodate more tubes than a
square (or rotated square) pattern. Furthermore, a triangular pattern produces
high turbulence and therefore a high heat-transfer coefficient. However, at the
typical tube pitch of 1.25 times the tube O.D., it does not permit mechanical
cleaning of tubes, since access lanes are not available. Consequently, a
triangular layout is limited to clean shell side services. For services that require
mechanical cleaning on the shell side, square patterns must be used. Chemical
cleaning does not require access lanes, so a triangular layout may be used for
dirty shell side services provided chemical cleaning is suitable and effective.

A rotated triangular pattern seldom offers any advantages over a

triangular pattern, and its use is consequently not very popular.

For dirty shell side services, a square layout is typically employed.

However, since this is an in-line pattern, it produces lower turbulence. Thus,
when the shell side Reynolds number is low (<2,000), it is usually
advantageous to employ a rotated square pattern because this produces much
higher turbulence, which results in a higher efficiency of conversion of pressure
drop to heat transfer.

As noted earlier, fixed-tubesheet construction is usually employed for

clean services on the shell side, Utube construction for clean services on the
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tubeside, and floating-head construction for dirty services on both the shell side
and tubeside. (For clean services on both shell side and tubeside, either fixed-
tubesheet or U-tube construction may be used, although U-tube is preferable
since it permits differential expansion between the shell and the tubes.) Hence,
a triangular tube pattern may be used for fixed-tubesheet exchangers and a
square (or rotated square) pattern for floating-head exchangers. For U-tube
exchangers, a triangular pattern may be used provided the shell side stream is
clean and a square (or rotated square) pattern if it is dirty.

Tube pitch :
Tube pitch is defined as the shortest distance between two adjacent tubes.
For a triangular pattern, TEMA specifies a minimum tube pitch of 1.25 times
the tube O.D. Thus, a 25-mm tube pitch is usually employed for 20 mm O.D.
tubes.
PT = do +C
For square patterns, TEMA additionally recommends a minimum
cleaning lane of 4 in. (or 6 mm) between adjacent tubes.
Thus, the minimum tube pitch for square patterns is either 1.25 times the tube
O.D. or the tube O.D. plus 6 mm, whichever is larger. For example, 20-mm
tubes should be laid on a 26-mm (20 mm + 6 mm) square pitch, but 25-mm
tubes should be laid on a 31.25-mm (25 mm 1.25) square pitch.

Designers prefer to employ the minimum recommended tube pitch,

because it leads to the smallest shell diameter for a given number of tubes.
However, in exceptional circumstances, the tube pitch may be increased to a
higher value, for example, to reduce shell side pressure drop. This is
particularly true in the case of a cross-flow shell.
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Tube Number and Length

Select the number of tubes per tube side pass to give optimum velocity 3-
5 ft/s (0.9-1.52 m/s) for liquids and reasonable gas velocities are 50-100 ft/s(15-
30 m/s) If the velocity cannot be achieved in a single pass consider increasing
the number of passes. Tube length is determined by heat transfer required
subject to plant layout and pressure drop constraints. To meet the design
pressure drop constraints may require an increase in the number of tubes and/or
a reduction in tube length. Long tube lengths with few tubes may give rise to
shell side distribution problems.

The number of tubes in an exchanger depends on the

 Fluid flow rates

 Available pressure drop.

The number of tubes is selected such that the

 Tube side velocity for water and similar liquids ranges from
0.9 to 2.4 m/s (3 to 8 ft/sec)

 Shell-side velocity from 0.6 to 1.5 m/s (2 to 5 ft/sec).

The lower velocity limit corresponds to limiting the fouling, and the
upper velocity limit corresponds to limiting the rate of erosion.
When sand and silt are present, the velocity is kept high enough to
prevent settling.
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Tube & Shell Exhaust Gas Cooler :

A tube and shell exhaust gas cooler is used on

diesel engines to reduce the NOx emissions.
A rectangular closely packed tube arrangement
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Insufficient Thermal Rating :

 If the output of the rating analysis is not acceptable, a geometrical
modification should be made

 If the required amount of heat cannot be transferred to satisfy

specific outlet temperature, one should find a way to increase the heat transfer
coefficient or increase exchanger surface area
 One can increase the tube side heat transfer coefficient by increasing
the fluid velocity - Increase number of tube passes

 One can increase the shell side heat transfer coefficient by decreasing
baffle spacing and/or baffle cut

 One can increase the surface area by

 Increasing the heat exchanger length
 Increasing the shell diameter
 Multiple shells in series

Insufficient Pressure Drop Rating :

 If the pressure drop on the tube side is greater than the allowable
pressure drop, then
 the number of tube passes can be decreased or
 the tube diameter can be increased which may result to
 decrease the tube length – (Same surface area)
 increase the shell diameter and the number of tubes

 If the shell side pressure drop is greater than the allowable pressure
drop then baffle spacing, tube pitch, and baffle cut can be increased
or one can change the baffle type.
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Main & Leakage Flow Streams :

 There are five different shell side flow streams in a baffled heat
Exchanger
 Stream A is the leakage stream in the orifice formed by the
clearance between the baffle tube hole and the tube wall.

 Stream B is the main effective crossflow stream, which can be

related to flow across ideal tube banks.

 Stream C is the tube bundle bypass stream in the gap between

the tube bundle and shell wall.

 Stream E is the leakage stream between the baffle edge and

shell wall.
 Stream F is the bypass stream in flow channel partitions due to
omissions of tubes in tube pass partitions.
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Basic Theory :
The fundamental equations for heat transfer across a surface are given
by:

Q = U A ΔTlm = w Cp(t) (t2 − t1)= W Cp(s) (T1 − T2) or W L

Where :
Q - heat transferred per unit time (kJ/h, Btu/h)
U - the overall heat transfer coefficient (kJ/h-m2 oC, Btu/h-ft2 ºF)
A - heat-transfer area (m2, ft2)
Δt lm - log mean temperature difference (oC, ºF)
Cp(t) - liquid specific heat tube side,
Cp(s) - liquid specific heat shell side (kJ/kg-ºK, Btu/lb-ºF)
w - tube side flow ,
W- shell side flow (kg/h, lb/h)

The log mean temperature difference ΔTlm (LMTD) for countercurrent

flow is given by:

LMTD = (T2out - T1in) - (T1out - T2in)

ln {[T2 - T1out]/[T2 - T1in]}

Where:
T1 - inlet shell side fluid temperature
T2 - outlet shell side fluid temperature
t1 - inlet tube side temperature
t2 - outlet tube-side temperature
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In design, a correction factor is applied to the LMTD to allow for the

departure from true countercurrent flow to determine the true temperature
difference.
ΔTm = Ft ΔTm

The correction factor is a function of the fluid temperatures and the

number of tube and shell passes and is correlated as a function of two
dimensionless temperature ratios

S = ( t2-t1 ) R = (T1-T2)
(T1-t1) , (t1-t2)

Kern developed a relationship applicable to any heat exchanger with an

even number of passes and generated
Discussion :
Formulas for Calculation
Co-current Flow heat balance:
mtCpt (t2 - t1) = msCps(T1 - T2) = q

Counter-current Flow heat balance:

mtCpt (t2 - t1) = msCps(T1 - T2) = q
where,
mt = mass flowrate of cold fluid in the tube (kgs-1)
ms = mass flowrate of hot fluid in the shell (kgs-1)
Cpt = specific heat of cold fluid in the tube (kJkg-1°C-1)
Cps = specific heat of hot fluid in the shell (kJkg-1°C-1)
t1, t2 = temperature of cold fluid entering/leaving the tube (°C)
T1, T2 = temperature of hot fluid entering/leaving the shell (°C)
Q = heat exchange rate between fluid (kW)
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The general equation for heat transfer across the tube surface in a shell and
tube heat exchanger:

q = Uo Ao Tm = Ui AiTm

where,
Ao = outside area of the tube (m2)
Ai = inside area of the tube (m2)
Tm = mean temperature difference (°C)
Uo = overall heat transfer coefficient based on
the outside area of the tube (kWm-2°C-1)
Ui = overall heat transfer coefficient based on
the inside area of the tube (kWm-2°C-1)

The coefficients Uo and Ui:

1 1 1 d o ln(d o d i ) d o d
     o
Uo ho hod 2k w d i hid d i hi

and,
1 1 1 d i ln(d o d i ) d d
    i  i
U i hi hid 2k w d o hod d o ho

where,
ho = outside fluid film coefficient (kWm-2°C-1)
hi = inside fluid film coefficient (kWm-2°C-1)
hod = outside dirt coefficient (fouling factor) (kWm-2°C-1)
hid = inside dirt coefficient (kWm-2°C-1)
kw = thermal conductivity of the tube wall material (kWm-1°C-1)
do = tube outside diameter (m)
di = tube inside diameter (m)
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LMTD (log-mean temperature difference):

T1  T2
Tlm 
T
ln 1 

 T2

From the data collected, the counter-current and co-current heat

exchanger’s exit temperature of the hot fluid is higher than the exit temperature
of the cold fluid. This shows that heat may not spontaneously transfer from a
colder body to a hotter body. The increase in flow rate of one of the stream will
results in an increase in the rate of heat transfer. Theoretically, the amount of
heat loss form the hot water should be equal to the heat gain by the cold water.
However, this cannot be done practically. This may because of the heat loss to
the surrounding, the heat loss in counter current flow is approximately 26% and
the heat loss in counter current flow is approximately 30% which is slightly
higher. Based on the calculation done, we found out that the values of LMTD
for co-current flow is higher than the counter-current flow. But, the overall heat
transfer coefficient for counter-current flow is higher than the co-current flow.
This mean that counter current flow heat exchanger has a higher effectiveness.

Fouling Considerations

Typical fouling coefficients are shown in Appendix VII. It can be shown

that the design margin achieved by applying the
combined fouling film coefficient is given by:
Af = 1+Uc
Ac hf
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Corrosion Fouling
Heavy corrosion can dramatically reduce the thermal performance of the
heat exchanger. Corrosion fouling is dependent on the material of construction
selection and it should be possible to eliminate altogether with the right choice.
However if economics determine that some corrosion is acceptable and no data
is available from past experience an allowance of 1/16 in (1.59 mm) is
commonly applied.
Experiment Methods and Materials
The apparatus used in this experiment include a Shell and Tube heat
exchanger, a cold water circuit consists of a 50L tank and centrifugal pump, a
hot exgaust gas circuit consists of 5HB Engine, temperature and flow rate
indicators.
Selection of tube material
To pream to transfer heat well, the tube material should have good thermal
conductivity. Because heat is transferred from a hot to a cold side through the
tubes, there is a temperature difference through the width of the tubes. Because
of the tendency of the tube material to thermally expand differently at various
temperatures, thermal stresses occur during operation. This is in addition to
any stress from high pressures from the fluids themselves. The tube material
also should be compatible with both the shell and tube side fluids for long
periods under the operating conditions (temperatures, pressures, pH, etc.) to
minimize deterioration such as corrosion.

All of these requirements call for careful selection of strong, thermally-

conductive, corrosion-resistant, high quality tube materials, typically metals,
including copper alloy,stainless carbon steel, non-ferrous copper
steel, alloy, Inconel, nickel, Hastelloy and titanium.[3] Poor choice of tube
material could result in a leak through a tube between the shell and tube sides
causing fluid cross-contamination and possibly loss of pressure.
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CALCULATION:

LMTD = (T2out - T1in) - (T1out - T2in)

ln {[T2 - T1out]/[T2 - T1in]}

( calculation only bending sir )

Data Analysis
The specific results for this experiment allow us to determine the heat
transfers, heat losses, heat transfer coefficient and LMTD values.

Shell & Tube Heat Exchanger

Tube O.D. (do) : 26 mm
Tube I.D. (di) : 24 mm
Tube Length (L) : 760 mm
Tube Count (Nt) : 4 (single pass)
Tube Pitch (pt) : 32 mm
Tube arrangement : square
Shell O.D. : 140 mm
Shell I.D. (Ds) : 134 mm
Material of Construction :mild steel
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q (kW) LMTD Ao Ai Uo Ui
1.3275 10.42 0.12 0.096 1.0616 1.3053
1.5471 11.75 0.12 0.096 1.0973 1.3491
2.1544 12.59 0.12 0.096 1.4260 1.7533
2.5968 13.05 0.12 0.096 1.6582 2.0388
2.5550 12.81 0.12 0.096 1.6621 2.0436

q (kW) LMTD Ao Ai Uo Ui
1.2305 11.79 0.12 0.096 0.8697 1.0693
1.5473 13.56 0.12 0.096 0.9509 1.1691
2.1544 13.91 0.12 0.096 1.2907 1.5869
2.5410 13.78 0.12 0.096 1.5367 1.8893
2.7620 13.60 0.12 0.096 1.6924 2.0808
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Overall Heat Transfer Coefficients for some common Fluids and Heat
Exchanger Surfaces

The overall heat transfer coefficient can be used to calculate the total heat
transfer through a wall or heat exchanger construction. The overall heat transfer
coefficient depends on the fluids and their properties on both sides of the wall,
and the properties of the wall and the transmission surface.

For practically still fluids - average values for the overall heat transmission
coefficient through different combinations of fluids on both sides of the wall
and type of wall - can be found in the table below:

Overall Heat Transmission

Transmission Coefficient
Fluid Fluid
Surface
(Btu/ft2 hr oF) (W/m2 K)

Water Cast Iron Air or Gas 1.4 7.9

Water Mild Steel Air or Gas 2.0 11.3

Water Copper Air or Gas 2.3 13.1

Water Cast Iron Water 40 - 50 230 - 280

Water Mild Steel Water 60 - 70 340 - 400

Water Copper Water 60 - 80 340 - 455

Air Cast Iron Air 1.0 5.7

Air Mild Steel Air 1.4 7.9

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Overall Heat Transmission

Transmission Coefficient
Fluid Fluid
Surface
(Btu/ft2 hr oF) (W/m2 K)

Steam Cast Iron Air 2.0 11.3

Steam Mild Steel Air 2.5 14.2

Steam Copper Air 3.0 17

Steam Cast Iron Water 160 910

Steam Mild Steel Water 185 1050

Steam Copper Water 205 1160

Steam Stainless Steel Water 120 680

 1 Btu/ft2 hr oF = 5.678 W/m2 K = 4.882 kcal/h m2 oC - Unit Converter

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TYPICAL FOULING FACTORS

COOLING WATER - Fouling Factors in [m2K/W]

cooling water < 50 ° C cooling water > 50 ° C
Conditions
cooled fluid < 120 ° C cooled fluid > 120 ° C

Water velocity v < 1 m/s v > 1 m/s v < 1 m/s v > 1 m/s

Type of Water

Sea 0.00009 0.00009 0.00018 0.00018

Brackish 0.00035 0.00018 0.00053 0.00035

Cooling tower with inhibitor 0.00018 0.00018 0.00035 0.00035

Cooling tower without inhibitor 0.00053 0.00053 0.00088 0.00070

City grid 0.00018 0.00018 0.00035 0.00035

River mimimum 0.00018 0.00018 0.00035 0.00035

River average 0.00053 0.00035 0.00070 0.00035

Engine jacket 0.00018 0.00018 0.00018 0.00018

Demineralized or distilled 0.00009 0.00009 0.00009 0.00009

Treated Boiler Feedwater 0.00018 0.00009 0.00018 0.00018

Boiler blowdown 0.00035 0.00035 0.00035 0.00035

SEVERAL FLUIDS - Fouling Factors in [m2K/W]

Group _______ Fluid __________________ Fouling Factor

Oil Gasoil 0.00009

Transformer 0.00018

Lubrication 0.00018

Heat Transfer oil 0.00018

Hydraulic 0.00018
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Gas and Vapour Hydrogen 0.00176

Engine exhaust 0.00176

Steam 0.00009

Steam with oiltraces 0.00018

Cooling fluid vapours with oil traces 0.00035

Organic solvent vapours 0.00018

Compressed air 0.00035

Natural gas 0.00018

Stable top products 0.00018

Liquid Cooling Fluid 0.00018

Organic heat transfer fluids 0.00018

Salts 0.00009

LPG, LNG 0.00018

MEA and DEA (Amines) solutions 0.00035

DEG and TEG (Glycols) solutions 0.00035

Stable side products 0.00018

Stable bottom products 0.00018

Caustics 0.00035

Vegetable Oils 0.00053

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TEMA DESIGNATION

Front End Stationary Rear End Stationary

Shell Type
Head Head

CHANNEL FIXED TUBESHEET,

A E ONE PASS SHELL L
AND REMOVABLE COVER LIKE 'A' STATIONARY HEAD

TWO PASS SHELL

BONNET FIXED TUBESHEET,
B F WITH LONGITUDINAL M
(INTEGRAL COVER) LIKE 'B' STATIONARY HEAD
BAFFLE

CHANNEL INTEGRAL WITH

TUBE-
SHEET AND REMOVABLE FIXED TUBESHEET,
C G SPLIT FLOW N
COVER LIKE 'C' STATIONARY HEAD
Shown: Removable Tube
Bundle only
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CHANNEL INTEGRAL WITH

TUBE-
SHEET AND REMOVABLE OUTSIDE PACKED FLOATING
C H DOUBLE SPLIT FLOW P
COVER HEAD

Shown: Fixed Tube sheet only

FLOATING HEAD WITH

SPECIAL HIGH PRESSURE
D J DIVIDED FLOW S BACKING DEVICE
CLOSURE
(SPLIT RING)

PULL THROUGH FLOATING

K KETTLE TYPE REBOILER T
HEAD
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F Charts for Common Shell-and-Tube

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LMTD CORRECTION FACTOR F :

F Correction Factor for a 1 – n Heat Exchanger

(where n is even)
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Shell-and-Tube Heat Exchanger (Single Pass) :

BEM This is the same type of heat exchanger as above, but with one tube pass.
Some examples of the TEMA designation for Heat Exchangers

There are four port in shell and tube heat exchanger. two inlet and two
outlet port. Engine exhaust gas connected to pipe is fitted in shell inlet. Water
flow pipe is connected to tubes inlet. Hot exhaust gas flow through the inside of
shell and cold water flow through the inside of tube at the time heat conduction
start. the heat will transfer from hot gas to cold fluid or cold fluid to hot fluid
so energy will be transfer both side. When a hot gas flow through a shell side
because of engine exhaust gas flow rate will be high. Baffle plate are used to
change flow of hot gas direction so heat transfer is accurate is more. Heat
transfer take place inside the heat exchanger .hot gas is change into cold gas and
cold fluid is change into hot fluid take a transfer inside a system .cold gas flow
in outlet port shell. Hot fluid flow in outlet port of tubes. Exhaust gas inlet
temperature is (120oc) is take heat conduction in shell to change the temperature
of gas outlet is (60oc). cold water inlet temperature is (30oc) is take a heat
conduction in tube to change the temperature of water outlet is(60oc).shell
outside cascut is used to avoid the leakage of water.
`

Basic Flow Arrangement :

`

Applications and Uses :

The simple design of a shell and tube heat exchanger makes it an ideal
cooling solution for a wide variety of applications. One of the most common
applications is the cooling of hydraulic fluid and oil in engines, transmissions
and hydraulic power packs. With the right choice of materials they can also be
used to cool or heat other mediums, such as swimming pool water or charge
air.[4] One of the big advantages of using a shell and tube heat exchanger is that
they are often easy to service, particularly with models where a floating tube
bundle (where the tube plates are not welded to the outer shell) is available. Can
also be used on fixed tube sheet heat exchangers.
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Conclusion
This experiment shows that the shell and tube heat exchanger follows the
basic law of thermodynamics. In parallel (co-current) flow configuration, the
exit temperature of the hot fluid is always higher than the exit temperature of
the cold fluid. In counter-current flow configuration, the exit temperature of the
hot fluid is also higher than the exit temperature of the cold fluid. However, in
counter current flow configuration, the exit temperature of the cold fluid is
higher than the exit temperature of the cold fluid in co-current configuration.
Hence, it is clear that for heat exchanger, counter current flow configuration has
a higher effectiveness than the co-current flow configuration. The experiment
shows that when the flow rate of one of the stream increases, the rate of heat
transfer will also increases. The amount of heat loss form the hot water is not
equal to the heat gain by the cold water due to the heat loss to the surrounding.
From the calculations done, the LMTD (log mean temperature difference) for
co-current flow is higher than the counter-current flow. However, the overall
heat transfer coefficient for counter-current flow is higher than the co-current
flow. As a conclusion, counter current flow configuration of heat exchanger is
more preferred for practical application. One of the application of heat
exchanger is oil cooler.
`

References :

 Fundamentals of Heat Exchanger Design Ramesh K. Shah &

Dusan Sekulic John Wiley & Sons, 2003

 Compact Heat Exchangers, 3rd Edition W.M. Kays & A.L.

London

 Heat Exchangers, Selection Rating & Design Sadik Kakac &

Hongtan Liu CRC Press, 2nd Edition, 2002

 Shell & Tube Heat Exchanger Design Software for Educational

Applications. Int. J. Engng. Ed. Vol. 14, No. 3, p 217-224, 1998
K.C. Leong, K.C. Toh, Y.C. Leong

 Wolverine Tube Heat Transfer Data Book www.wolverine.com

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APPENDIX
`

APPENDIX

Dimensional Data For Commercial Tubing

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APPENDIX

Dimensional Data For Commercial Tubing :

`

APPENDIX

TUBE DIMENSIONAL DATA :

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APPENDIX
SHELL TUBE COUNT DATA :
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