Design of A Heat Exchanger Using HTRI
Design of A Heat Exchanger Using HTRI
Design of A Heat Exchanger Using HTRI
Body:
I am writing this Blog to help modelling Heat Exchanger in HTRI step by step. We can design general shell & tube type heat exchanger, Air cooler, PHEs, Jackated Pipe exchanger, Hairpin type
exchanger, Spiral plate type exchanger, Economiser & Fire heaters by using HTRI but I want to keep this blog restricted to Shell & tube type exchanger only
1.1.
Process Parameters
Input flow rate, temperature & vapour fraction at inlet / outlet conditions and the allowable pressure drop for shell & tube side.
For liquids, vapor fraction is 0; for gas it is 1 and for two phase it is between 0 & 1.
1.2.
Geometry
TEMA type
As given in Process data sheet (if not mentioned, then it shall be decided based on type of fluid, condition etc.)
Orientation
Orientation may be horizontal, vertical or inclined with an angle between 0 and 90 deg.
Hot fluid side
Hot fluid shall be either on the shell side or on the tube side
Tube type
Plain or finned (for shell & tube generally plain tubes are used)
Tube length
In design mode, enter the length & design the exchanger for various shell IDs. Standard tube lengths available in FPS units are 4, 6, 8, 10, 12, 14, 16, 18, 20, 22 and 24 feet. In MKS unit, tube
lengths can be used in steps of 500 mm. Sometimes, it may be required to use FPS standard tube lengths in MKS unit (for e.g. 6096 mm, 3048 mm, etc.)
Note1: Sometimes odd tube length would be acceptable for reboiler and small exchangers.
Note2: Design of exchanger will be different if selection of grid for tube length is different. If we decide only 2,4 & 6 Meter tube to be used then we have limitation of tube length. Some time we may
land up with design lesser DP utilization because of tube length constrain.
Now a days tubes in any length are available, after discussion with lead engineer we can select odd tube length like 3500 or 3600 mm. At the end we should select tube length such that there will
be fewer inventories of tubes in store.
Note3: Some time for high pressure exchanger (i.e. D type or C type exchanger for which design pressure is more than 70 to 80 Kg/cm2) calculated tube sheet thickness by HTRI is on lower side
than calculated thickness mechanically because some time tube sheet is to be designed full design pressure but HTRI is consider for differential design pressure. For such exchanger we should add
additional tube sheet thickness in geometry panel of HTRI during design and we should specify tube length excluding tube sheet thickness on process data sheet. Also we should mention only
effective heat transfer area and clearly explain all these points in notes.
Effective Tube length
This is the value used for heat transfer and need not be entered. HTRI calculates tube sheet thickness and also the effective tube length.
Effective tube length = Total tube length Tube sheet thickness Tube projection
Surface Area Gross
Total installed area
(Number of tubes x total tube length x p x tube OD)
Surface Area Effective
Total installed area.
(Number of tubes x effective tube length x p x tube OD)
Shell ID
In design mode this input is not required. HTRI calculates.
If an exchanger has to be designed for a fixed shell ID then input the ID and vary tube length by using grid design option. (Refer grid design option 4.2.6)
Tube OD
Generally 19.05, 25.4, 31.75, 38.1, 50.1 mm
Note: If tube OD is specified in mm then tube thickness should be in mm i.e. 1.5 mm,2 mm 2.5 mm, 3.0mm (as per project design basis)
And if tube OD is specified in inches then tube thickness will be in BWG standard i.e. 12,14,16,18,BWG etc. We can convert BWG thickness in to equivalent mm. Never specify tube OD in mm &
thickness in BWG or tube OD in inches and thickness in mm.
Tube Pitch
Generally 1.25 times tube OD. Other values can also be specified.
Note: Some time to elimate vibration pitch can be more than 1.25 times tube OD.
Tube layout
Refer Kern
Tube passes
Not required for design case.
(For floating head and U-tube, even number of passes shall be entered, viz. 2, 4, 6, 8 etc.)
Note : Some time for floating head exchanger single pass can be accepted.
Tube count
Not required for design case.
Tube material
Tube MOC shall be selected from HTRI data bank.
Note: For Refinery MOC of baffles, tube supports, tie-rods, spacers: ( same as tube side MOC) but for inorganic chemical plant we can use MOC of baffles tube support, tie-rods spacers same as shell
MOC.You should discuss with your senior and finalise if there is any issue regarding MOC.
Baffle type
Various baffle types are Single, Double, NTIW and Rod. Baffle type need not be specified for design case.
Baffle cut
Baffle cut is specified with respect to shell inlet nozzle axis and can be either vertical or horizontal (if the baffle cut is perpendicular to the nozzle axis, then the cut is horizontal and if the cut is
PIPING
Process
Exchanger Duty
Enter actual exchanger duty
Duty Multiplier
Enter the duty multiplier
For e.g. for 10% over design on duty, enter 1.1
Fouling resistance
Enter the value mentioned in data sheet. If this value is not available in the datasheet, then the same should be taken from published literature, reference books, like Process Heat Transfer by D.Q.
Kern.
1.5.
(b)
Component by component
(c)
User specified
(b)
(c)
Programme calculated
Composition units
Moles or mass
Flash type
Differential (separate and not in contact) or integral (well mixed and in thermal and chemical equilibrium)
1.6.
Grid Design
Geometry
a.
Shell ID
Enter the minimum and maximum shell ID and either the number of steps or the step size in mm or inch
b.
Baffle spacing
Enter the minimum and maximum baffle spacing and either the number of steps or the step size in mm or inch
c.
Tube passes
Enter the minimum and maximum number of passes and odd or even passes.
d.
Tube length
Enter the minimum and maximum tube length and either the number of steps or the step size in mm or inch
e.
Pitch ratio
Enter the minimum and maximum pitch ratio and either the number of steps or the step size in mm or inch
f.
Tube diameter
Enter the minimum and maximum tube diameter and either the number of steps or the step size in mm or inch
g.
Shell type
Baffle type
amplitude. Try changing the shell class J12 exit diameter increases or shell. Not to be missed. 7. The inlet unsupported span length (inlet baffle spacing+central
baffle spacing)exceeds the TEMAmaximum unsupported span length. Non-support plate spacing length at the entrance (inlet baffle spacing, combined with the
Center baffle spacing) exceeds the maximum length without support plate spacing TEMA. Try reducing the baffle spacing. Heat exchanger baffle spacing is
generally isometric. Not to be missed. 8. The vapor specific heat of the hot fluid is calculalated in the area of the critical temperature.the linear interpolation of the
vapor specific heat and the sensible heat duty may be inaccurate in this region.specified the vapor specific heat and/or the heat release curve for this case. Heat
flow calculation of gas compared to heat at critical points. In this range the linear interpolation method is used to get the gas heats heat load may not be accurate.
In this case specify the latent heat of vapor or hot fluid curves. Can be ignored. 9. A differential flash is recommended for two-tube pass intube condensation
unless a U-tube bundle is used because of potential phase separation in the header. Condensation in the two tube tube recommends using the differential method.
Unless you are using a u-tube. Because there may be the potential for vapor at the head part. Change calculation in the hot/cold fluid properties>Flash type type.
Not to be missed.