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Process STD 301 PDF
Process STD 301 PDF
TABLE OF CONTENTS
PAGE
NOTE:
1. Appendices appear at the end of each appropriate section. The first page only is
indicated. See List of Figures and Tables to locate individual items.
TABLE OF CONTENTS
LIST OF FIGURES
TABLE OF CONTENTS
LIST OF TABLES
1.0 INTRODUCTION
Shell and Tube Heat Exchangers, as indicated by the name, consist essentially of
a bundle of tubes, contained in a shell of somewhat greater diameter. One fluid
flows through the tubes and the other around the tubes through the shell. The
majority of heat exchangers employed in the petroleum refineries and chemical
plants are of this type.
The purpose of this standard is to furnish information on such aspects of shell and
tube heat exchangers as:
Efficient heat exchangers are essential for economic operation of refineries. They
are also a significant proportion of the capital cost of a plant. For a refinery the
exchangers are 5 to 6% of the total materials cost. For individual units they may
cost even more, for example, on a crude unit the proportion is 10 to 12%.
After the process engineer has selected the process conditions, the exchanger
process data sheet from which the exchanger engineer initiates detailed design
should be prepared. The process specification must be sufficient to ensure that all
the process requirements are met. On the other hand it should avoid
unnecessarily restricting the heat exchanger engineer. For example, if either of the
fluids may be in the tube then the specification should say so, as a more economic
design may be investigated. Consideration should be given to whether a shell and
tube exchanger is the most suitable type for the particular duty. A type to consider
when the area is less than 10M2 (100 ft2) is the double pipe exchanger. Compact
exchangers such as the plate and the spiral exchangers also offer considerable
advantages and are often cheaper when an expensive material is required. For
heat exchangers other than the shell and tube type, refer to Process Standard 303
for information.
This section deals with general aspects of shell and tube heat exchanger services
most frequently encountered in refineries and chemical plants. Service
classifications by the functions they fulfill in a process are briefly described below.
The basic exchanger design principles for the various service classifications are
fundamentally quite similar, particularly with regard to heat transfer coefficients and
mean temperature difference (M.T.D.), and are covered under Section 4.0. The
various types of shell and tube exchanger construction commonly used for the
different services are covered under Section 3.0. It should be noted that there may
be a certain overlapping among the different service classifications since they are
sometimes not quite readily distinguishable. The classifications given below should
only serve as a general guideline.
2.1 Exchangers
The term exchanger is often used in a restricted sense, being applied
specifically to equipment employed to interchange heat between a hot
process stream and a cold process stream. Steam and cooling water are
utilities and are not considered in the same sense as recoverable process
streams. The hot process stream may be a product stream, a pump around,
or a reactor effluent stream. The cold process stream may be a feed stream
to a process unit, a recycle gas stream or a feed stream to a tower or reactor.
2.2 Preheaters
These exchangers include preheat services involving a process stream
and a utility or non-process stream. For instance, a cold stream, such as
the feed to a tower or a reactor, is heated with either steam, Dowtherm
fluid or circulating hot oil. A Boiler Feed Water Preheater using a hot
process stream, such as FCC Fractionator Pumparound or Bottoms, is
another example.
2.3 Vaporizers
2.3.1 Reboilers
These exchangers operate in conjunction with a tower to vaporize
enough liquid to assure stripping of the bottom product as well as
vaporization of the overhead product and the reflux required for
fractionation. The heating medium is usually placed in the tube
side. There are various types of reboilers, which are different in
operating principles and/or construction. Detailed discussions on
the applications of the various reboiler types follow in Section 3.5.
The common types are briefly described below.
A. Thermosyphon Type
B. Kettle Type
C. Pump-thru Type
2.3.2 Chillers
Chillers may be employed to cool a liquid stream or to condense a
vapor stream by vaporization of a refrigerant. The stream to be
cooled or condensed is generally routed through the tubes, while
the low temperature boiling refrigerant vaporizes from a pool of
liquid in the shell. Chiller operation is very similar to that of a
kettle type reboiler even though the objective is entirely different.
Chiller construction also resembles that of a kettle type reboiler in
that vapor disengaging space for the boiling refrigerant is provided
in the shell. Frequently, temperatures are such that it is possible to
use fixed tube sheet construction.
2.3.3 Evaporators
Under this heading are included desalination evaporators and
chemical evaporators. The former are used for the desalination of
sea water; the latter for such service as the concentration of
solutions
A. Location of Steam
B. Position of Shells
D. Typical Applications
2.4 Coolers
This class is comprised, in general, of units in which hot process streams
are cooled with water. All or most of the heat is transferred as sensible
heat. In general, this heat is at too low a temperature level to be
recovered economically and consequently, is discarded to cooling water.
B. Total
1. Isothermal
B. Pressure Heaters
3.2.1 General
Figure 3-6 shows the designation of the various front end
stationary heads, shells and rear heads as recommended by
TEMA.
Reference to Figures 3-1 to 3-5 will show that these have the
TEMA designations indicated. Thus Figure 3-1 shows an AES
type. This means that the exchanger has a stationary head and
removable channel and cover, a one pass shell and the rear head
is a floating head with a split ring backing device.
Type BEU
Size 23-240
F. Chiller
Table 3-1 lists the design features of the various types of tube side
construction. The common rear end constructions include the floating
head, the U-tube and the fixed tube sheet. The principal differences and
relative advantages and disadvantages of the various types of tube side
construction are discussed below:
A Multipass Tubes
1. Split Ring
2. Full Bolted
With single pass tube side construction, the tube side inlet
and outlet are necessarily at opposite ends of the
exchanger. The fact that one of these connections,
normally the outlet, must be at the floating end, introduces
complications. The most common types of construction
employed in these circumstances to provide for differential
thermal expansion are discussed below.
Here the tubes resemble hairpins, with both tube ends rolled into
the fixed tubesheet and with the Uat the opposite end of the
shell.
Here both front and rear tubesheets are fixedor welded to the
shell.
Fixed tubesheet construction is the only type which allows the use
of an odd number of tube passes (besides single pass) with a
single pass shell. For example, a three pass tube layout may be
employed.
Its disadvantages are that without a shell expansion joint this type
is limited to a maximum mean temperature difference of 50F
between the shell and the tubes (See Section 4.7 for method of
calculating the mean temperature difference). This limit is due to
both tubesheets being fixed to the shell. At higher differential, the
problem can be overcome by fitting an expansion bellows to the
shell, but some clients will not accept this.
A. Finned Tubes
1. G-fin Tubes
B. Bayonet Tubes
The majority of exchangers are of full bundle type with the bundle
essentially filling the shell (no provision for vapor disengaging in the
exchanger).
3.5 Reboilers
3.5.1 General
Natural circulation reboilers can be divided into 4 basic types.
They are:
headroom, hence, lower column skirts. With this type, only the
liquid from the bottom tray (trapout) flows to the reboiler. That is,
the reboiler feed consists entirely of the portion of trapout liquid to
be vaporized and the bottom product. As indicated before, this
type is most frequently employed in clean service with low
vaporization. TEMA G and H type shells are normally used for
this service.
Floating
Floating Head Floating Head Floating Head Head
Type of Fixed Pull-Through Outside Packed Split Outside
Design U-tube Tubesheet Bundle Lantern-Ring Backing Ring Packed
Stuffing Box
Relative Cost
Increases From
(A) Least Expen-
sive through
(E) Most
Expensive A B C C D E
Provision for
Differential individual tubes expansion joint
Expansion free to expand in shell floating head floating head floating head floating head
Removable
Bundle yes no yes yes yes yes
Replacement
Bundle Possible yes not practical yes yes yes yes
Tube Exteriors
With Triangular chemically
Pitch Cleanable chemically only chemically only chemically only chemically only chemically only only
Double
Tubesheet
Feasible yes yes no no no yes
no no
practical practical
limitation (for limitation (for
single pass, single pass,
any practical floating head floating head
Number of even no practical requires packed limited to single requires packed no practical
Tube Passes number possible limitations joint) or 2 pass joint) limitation
Internal Gaskets
Eliminated yes yes no yes no yes
1.0 Table 3-1 Design Features of Various Types of Tube Side Construction
4.1 General
This section describes information needed for completing heat exchanger
process specifications. A standard Shell and Tube Heat Exchanger
Requisition Form* has been filled out and is included as Figure 4-1 in the
Appendix. The data shown on this form is that required by the Foster
Wheeler Heat Transfer Equipment Engineering Group for designing or
rating an exchanger.
For exchangers where the flow of the hot and cold fluids is true counter or
concurrent, !T is equal to the log mean temperature difference (LMTD).
In most commercial exchangers, the use of shell baffles and multiple tube
passes causes the flow to be partially counter and partially concurrent.
Since the concurrent flow results in a lower !T a correction factor (F), must
be applied to the countercurrent LMTD, i.e., !T (effective) = LMTD x F (F
"# 1.0). The correction factor is also a function of the number of exchanger
shells connected in series.
Note (1) the ratio Ai/Ao = ID of tube/OD of tube for plain tubes only.
rw = l/12K where
l = wall thickness, in
Ao = $doLN
N = number of tubes
4.3 Temperatures
Criteria for establishing the heat exchanger operating temperatures
arediscussed below:
1. Maximum values
a. Salt Water
b. Fresh Water
c. Box Coolers
2. Actual Values
t2 = T2; t2 = T2 +! t; t2 = T2 - !t
case 3 = 8,500,000/[(100-90) x
500]=1,700 GPM
= $63,750 + $48,960
= $112,710
= $42,525 + $32,660
= $75,185
= $127,500 + $97,920
= $225,420
a. Routing Fluids
1. Cooling water
1. Water Service
Corrosion
Severity of O.D. Fouling
BWG Allowance,
Service Inches Factor
Inches
1. Triangular
2. Square in line
3. Square at 45 Degrees
a) Rotated bundle
T2 ! t2
! t,=T 2-t,
! t1 - ! t2
! T = LMTD =
* ! t1 '
ln (( %%
) ! t2 &
Notes
a. Countercurrent Flow
It should be noted that when t2 = T2, the F value for a single shell
pass exchanger is usually 0.80 (never less, sometimes slightly
greater). If there is a constant temperature on one or both sides
of the exchanger, i.e. isothermal condensation or vaporization
(steam) then F=1.0.
Q1 + Q 2 + Q 3
!T = weighted LMTD =
Q1 Q2 Q3
+ +
LMTD1 LMTD 2 LMTD3
For cases where sharp changes in the curve occur as at the onset
of condensation etc., it is convenient to select this point as the
terminus of a zone.
X = (B-t)/(A-t)
R = (A-B)/ n(t0-t)
(1) X = as above
(2) R = as above
* 1 '
(3) P=( % (1 - X 1/n )
) R &
In practice, allowable values for pressure drop are usually estimated by the
process design engineer rather than calculated. Pressure drop
considerations for various fluids are discussed below:
4.8.1 Liquids
Table 4-2 gives suggested pressure drop values for both the shell
and tube sides of exchangers.
4.8.2 Gas
Pressure drop often depend on compressor considerations.
Largely because of the high investment and operating costs for
compressors as compared to pumps, optimum values are much
lower for gases than for liquids.
4.8.3 Condensers
a. Overhead Condensers for Towers operating above
Atmospheric Pressure.
1. Partial Condensation
2. Total Condensation
4.8.4 Reboilers
a. Kettle Type
b. Thermosyphon Type
In the case of recirculating type reboilers, the ratio of the
recirculated liquid to the vapor formed is normally about
4:1. It may be considerably higher, ie., 10:1, in order to
avoid an excessively high bottom product temperature.
1. Horizontal units (once-thru and recirculating)
For these units, TSE (thermosyphon effect) is
specified. This means the exchanger manufacturer
is to calculate and guarantee the pressure drop in
his exchanger for the specified flow quantities. The
pressure drop is normally low, i.e. 0.25 - 0.5 psi, due
to unbaffled exchanger construction. High heat
transfer coefficients are obtained due to
vaporization, even at the velocities corresponding to
these low pressure drop values. Eventually the
hydraulics of the reboiler circuit must be checked to
assure sufficient static head is available to
overcome the pressure drops in the reboiler and the
piping. Refer to Process Standard 203 for reboiler
hydraulics.
2. Vertical Units
Occasionally a vertical unit is employed, with
vaporization occurring in the tubes. Such a unit will
generally be of the recirculating type. The location
of the top of the reboiler, with respect to the bottom
of the tower and the lower liquid level therein, is
generally fixed by the reboiler-tower connection.
The principal factor which can then be varied to
balance driving force (static head) against friction
losses is the tube length. As the tube length is
decreased, the number of tubes in parallel increases
and a balance is obtained.
1
U clean = where rtotal fouling = ro + ri (Ao/Ai)
1
- r total fouling
Ud
Typical rates are indicated in Table 4-4 for many of the services
encountered in the following plants: crude units, catalytic cracker
fractionation sections, catalytic cracker vapor recovery units, HF
alkylation units with vapor recovery, coker units, hydrotreaters and
catalytic reformers - naphtha and gas oil feeds, amine
regeneration units - MEA, DEA & MDEA, shale oil upgrading
fractionating sections and some miscellaneous services and
applications not necessarily associated with a particular type of
plant. Note that these typical overall design rates are based upon
using bare tube bundles.
FIGURE 4-1
REQUISITION
TABLE 4-1
Notes:
(1) Under the following circumstances, !Ps approaching the higher recommended
values should be employed: when !T is small, say 50 or less; when the temperature
range is large, i.e., above 200F.
(2) Calculated tube side pressure drop values are subject to greater variation than shell
side values, due to the nature of tube bundle construction.
(3) It must be realized that little can be gained by specifying increased pressure drop for
one fluid in an exchanger when the other fluid has a significantly lower film
coefficient.
(4) For gravity flow, the pressure drop is usually limited to 1 - 2 psi.
The following tables present typical fouling resistances referred to the surface on which
they occur. In the absence of specific data for setting proper resistances, the values
tabulated below may be used.
LIQUIDS
Refrigerant Liquids .................................................................................................. . .001
Hydraulic Fluid......................................................................................................... . .001
Industrial Organic Heat Transfer Media................................................................... . .001
Molten Heat Transfer Salts...................................................................................... . .0005
LIQUIDS
MEA & DEA Solutions.................................................................... . .002
DEG & TEG Solutions .................................................................... . .002
Stable Side Draw and Bottom Product........................................... . .001
Caustic Solutions ........................................................................... . .002
Vegetable Oils ................................................................................ . .003
LIQUIDS
Lean Oil .......................................................................................... . .002
Rich Oil........................................................................................... . .001
Natural Gasoline & Liquefied Petroleum Gases............................. . .001
Crude Oil
0 - 1990F 2000- 2990F
Velocity Ft./Sec. Velocity Ft./Sec.
Under 2-4 4 Ft. Under 2-4 4 Ft.
2 ft. Ft. And Over 2 Ft. Ft. And Over
Dry .003 .002 .002 .003 .002 .002
Salt* .003 .002 .002 .005 .004 .004
**Depending on charge characteristics and storage history, charge resistance may be many times this value.
CRUDE UNITS
CRUDE UNITS
CATALYTIC CRACKER
Fractionation Ud Notes
Preheat:
Fresh Feed-Cracked Naphtha 65 Feed in Shell
Fresh Feed-LCO 53 Feed in Shell
Fresh Feed-HCO 50 Feed in Shell
Fresh Feed-Clar. Oil )
Fresh Feed-Slurry ) 48 - 58 Feed in Shell
Fresh Feed-Bottoms )
Overhead Trim Condenser 55 - 65
H.P. Steam Generator-Btms. P.A. 85 - 90 Kettle
Bottoms-BFW Preheat 55 - 60 Contain 2 Wt.%
Catalyst Fines
Box Cooler-Bottoms 15 - 30
Clarified Oil Cooler 50
Sidestream Coolers 75 - 85
Fractionation Ud Notes
Slurry Settler Purge Cooler 70
Flue Gas Waste Heat Boiler 15
Rich Oil-LCO Exchanger 55
LCO Trim Cooler 71 - 75
H.P. Steam Generator- HCO P.A. 82 - 92 Kettle
BPA-LCO Reboiler 55
LCO-BFW Preheat 90 - 105
COKER UNITS
Fractionation Ud Notes
Fresh Feed-Stripped Heavy Coker Gas 20 Vacuum Residue Feed in
Oil Shell Side
5 Vacuum Residue Feed in
Tube Side
8 Reduced Crude Feed in
Tube Side
Fresh Feed-Heavy Coker Gas Oil P.A. 33 Preheated Vacuum Resi-
due Feed in Shell Side
6.5 Preheated Vacuum Resi-
due Feed in Tube Side
9.5 Preheated Reduced
Crude Feed in Tube Side
Fresh Feed-Stripped Light Coker Gas 20 Vacuum Residue Feed in
Oil Shell Side
Lean Sponge Oil (Light Coker G.O.) - 52
Rich Oil
Lean Sponge Oil (Coker Kerosene) - 61
Rich Oil
Lean Sponge Oil (Coker Kerosene) 64
Cooler
Stripped Heavy Coker Gas Oil - 55 - 67
BFW Preheat
Heavy Coker Gas Oil P.A. - M.P. Steam 81 - 85 Kettle
Generator
Fractionator Overhead Trim Cooler 70 TEMA JShell
Hydrotreaters Ud Notes
Naphtha Feed:
Reactor Effluent-Feed 46 - 56 Combined Feed (H2+HC)
Reactor Effluent-Stripper Reboiler 67
Reactor Effluent Trim Cooler 91 - 106
Reactor Feed-Dowtherm A Preheater 56
Reactor Feed-Stripper Bottoms 62
Stripper Feed-Bottoms 75 - 82
Stripper Reboiler-Dowtherm A 85
Gas Oil Feed:
Cold Feed-Fractionator Overhead 24
Reactor Feed-Hot High Pressure 41 Hydrotreater
Separator Vapor
Reactor Feed-Effluent 36 Preheat Services
Reactor Feed-Light Diesel Oil 55
Reactor Feed-Fractionator Bottoms 80
Reactor Effluent Waste Heat Boiler 87 Kettle Type
(H.P.)
High Pressure Vapor Condenser 76 Water Cooling
Hydrotreaters Ud Notes
Fractionator Overhead Trim Cooler 43
Light Diesel Oil Stripper Overhead 58
Condenser
Light Diesel Oil Product Cooler 83
Heavy Diesel Oil Stripper Overhead 58
Condenser
Heavy Diesel Oil Product Cooler 67
Fractionator Bottoms-Diesel 47
Stripper Reboiler
Cold Fractionator Feed-Bottoms 32
Hot Fractionator Feed-Bottoms 42
Fractionator Bottoms Waste Heat 74 Kettle Type
Boiler (L.P.)
Catalytic Reformers
Platformer Reactor Effluent-Feed 60 Combined Feed (H2+HC),
large cooling/heating
range
Powerformer Reactor Effluent-Cold Feed 72 Combined Feed (H2+HC)
-Hot Feed 101 Combined Feed (H2+HC)
Reactor Effluent-Stabilizer Reboiler 82
Reactor Effluent-Separator Liquid 53
(Cold Stabilizer Feed)
Reactor Effluent-Recycle Gas 50
MISCELLANEOUS APPLICATIONS
Ud Notes
Compressor Jacket Water Cooler 200
Compressor Intercoolers (Air & Gas) 15 - 30 Ud increases with operating
pressure and percent
condensed.
Steam-Oil Preheater 90 - 110 May be lower if oil is very
viscous.
1. Determine Type
With steam heating use a U-tube exchanger with steam in the tube.
Since shellside fluid is dirty use square pitch.
2. Determine h
ho = 140
4. Calculate Ud
1 1 1
= + ro + rw + + ri
Ud ho Ai Ai
hi
Ao Ao
For plain 3/4" carbon steel tubes using normal thickness of 14 BWG
Ai ID
= = 0.781
Ao OD
1 1 1 .0005
= + 0.002 + +
Ud 140 1500 x 0.781 0.781
= 0.01063
Ud = 94.0
5. Calculate LMTD
For condensing steam with some superheat the saturation
steam temperature should be used.
IN OUT
266 - 66 200
LMTD = = = 1441 F
ln (266/66) 1.39
6. Calculate Area
FOSTER WHEELER ENERGY LIMITED 2002
PROCESS STD 301
FOSTER WHEELER HEAT TRANSFER PAGE 5.0-5
SHELL AND TUBE REV 10
PROCESS PLANTS DIVISION HEAT EXCHANGERS DATE JULY 2002
Q 20.00 x 106
A= = = 1,477 ft 2
U !T 94 x 144
Exchanger is 3/4" tubes 1" square pitch with 2 passes on tube side.
From table 7-2, 3/4" - 14 BWG tube has a surface area per linear ft. of
0.1963 ft2. Therefore,
From Table 7-3 it can be found that a 20 ft. bundle length will require
an exchanger shell of 35.0" I.D. and for 16 ft. bundle length, a 39.0"
I.D. exchanger shell.
For a required surface area the use of longer and therefore fewer
tubes requires a smaller shell diameter and is the most economical
design. Also, most refiners have standardized the use of 20 ft. tubes.
The exchanger as designed by the Heat Transfer Equipment
Engineering Group was 31" x 20' containing an area of 1,126 ft2.
6.1 General
The objective of the process engineer completing the exchanger
specification sheet is to define the duty and process requirements of the
exchanger. Mechanical detail should be the minimum necessary, so that
the heat exchanger engineer has the maximum flexibility to provide the
most economic design. If however, for process reasons or licensor
specifications, there are definite mechanical requirements, these must be
specified. In certain cases where the service is special or there is a lack of
data, it may be necessary to refer to a previous design that has provided
successful, and this requirement must be made clear. In specifying an
exchanger it is essential to consider the range of operation in order to
select the limiting case. Usually this is fairly obvious, but where it requires
detailed evaluation the alternative cases must also be specified.
9. Remarks:
2 Fluids may be reversed, i.e. hot fluid may be in either the shell or tube side
if they may lead to a more economical design.
2 Total allowable pressure drop. If a group of exchangers have the same fluid
going through them, then a total allowable pressure drop for the fluid over the
entire group of exchangers can help lead to a more economical design.
2 Trace contaminants; for example a few ppm of ammonia will mean that copper
or copper bearing materials are unacceptable.
2 To account for uncertainties in heat and material balance data, the following
notes, if appropriate, may be used:
To ensure that the process specifications have been properly followed in the
equipment and associated piping design phase, a follow-up on exchanger
requisitions is required by the process engineers. The primary objective of
the follow-up is to learn whether the final exchanger design/requisitions in the
project stage have resulted in any adverse effect in meeting the hydraulic
requirements. The following items, in particular, shall be checked:
Any variation from the process specification found on the final exchanger
requisitions shall be brought to the attention of the responsible project
engineer or exchanger designer and resolved accordingly. It may require a
process check on the hydraulic system involved to determine whether
changes in the exchanger requisitions and/or other items, such as pumps,
control valves, piping are required. In addition, the process engineer is
responsible to carry out a detailed hydraulic recheck on all pumping and
critical hydraulic systems.
7.2.1 General
Frequently, during the process design or study phase of a
project, it is necessary to make preliminary estimates of the
surface area and dimensions of individual exchangers. Such
estimates are required to establish the number of shells for
each exchanger service. The result can then be used to
estimate plot plan requirements and to prepare process
economic studies.
7.4.1 General
The pressure and temperature levels of the process fluids will
undoubtedly have their effects on the mechanical design of a
shell and tube exchanger. Sometimes the design pressure and
temperature requirements imposed on an exchanger may
become an important factor in the selection of the shell side
and tube side construction types for the service. Refer to
Section 3.0 for the features of the various types of shell side
and tube side construction.
For steam generators the steam side design pressure and PSV
set pressure is set by the design pressure of the plant steam
system. According to the ASME Boiler and Pressure Vessel
Code, Section I, steam generators usually require two PSVs
(see Process Standard 602, Safety, Relieving Devices).
TABLE 7-1
THE TEMA STANDARDS - 1978
A COMPARISON OF CLASSES R, C AND B
Para Topic R C B
graph
1.12 Definition for the generally severe requirements For the generally moderate requirements of for general process service.
of petroleum and related processing commercial and general process applications.
applications.
1.51 Corrosion allowance on carbon steel 1/8 inch 1/16 inch 1/16 inch
2.2 Tube diameters 3/4, 1, 1 1/4, 1 , and 2 inch od R + 1/4, 3/8, and 5/8 R + 5/8
2.5 Tube pitch and minimum cleaning lane 1.25 x tube od. 1/4 inch lane. R+ 5/8 tubes may be located 1.2 x tube od R + lane may be 3/16 inch in 12 inch and smaller
shells for 5/8 and 3/4 tubes.
3.3 Minimum shell diameter 8 inch tabulated 6 inch tabulated 6 inch tabulated
4.42 Longitudinal baffle thickness 1/4 inch minimum 1/8 inch alloy, 1/4 inch CS 1/8 inch alloy,
1/4 inch carbon steel
4.71 Minimum tie rod diameter 3/8 inch 1/4 inch in 6-15 inch shells 1/4 inch 6-15 inch shells.
5.11 Floating head cover cross-over area 1.3 time tube flow area Same as tube flow area Same as tube flow area
0
5.31 Lantern ring construction 375 F maximum. 600 psi maximum (same as TEMA R)
300 psi up to 24 inch dia. shell
150 psi for 25-42 inch shells
75 psi for 43-60 inch shells
6.2 Gasket materials Metal jacketed or solid metal for Metal jacketed or solid metal (same as TEMA C)
(a) internal floating head cover. (a) internal floating head.
(b) 300 psi and up. (b) 300 psi and up.
(c) hydrocarbons. Asbestos permitted for 300 psi and lower
pressures.
6.32 Peripheral gasket contact surface Flatness tolerance specified. No tolerance specified. No tolerance specified.
7.131 Minimum tubesheet thickness with Outside diameter of the tube. 0.75 x tube od for 1 inch and smaller. (same as TEMA C)
expanded tube joints 7/8 inch for 1 1/4 od
1 inch for 1 od
1.25 inch for 2 od
0
7.44 Tube Hole Grooving Two grooves Above 300 psi design pressure: above 350 F (same as TEMA R)
design temp.-2 grooves
7.51 Length of expansion Smaller of 2 inch or tubesheet Smaller of 2 x tube od or 2" (same as TEMA R)
thickness
7.7 Tubesheet pass partition grooves 3/16 inch deep grooves required Over 300 psi 3/16 inch deep grooves required or (same as TEMA C)
other suitable means for retaining gaskets in
place
9.3 Pipe Tap Connections 6000 psi coupling with bar stock plug 3000 psi coupling 3000 psi coupling with bar stock plug
9.32 Pressure Gage Connections required in nozzles 2 inch & up. (shall be specified by purchaser) (same as TEMA R)
9.33 Thermometer Connections required in nozzles 4 inch & up. (shall be specified by purchaser) (same as TEMA R)
9.1 Nozzle construction no reference to flanges same as TEMA R All nozzles larger than one inch must be flanged.
10.1 Minimum bolt size 3/4 inch inch recommended. smaller bolting may be used 5/8 inch
TABLE 7-2
HEAT EXCHANGER TUBE DATA
2
Wall Surface area per linear ft, ft
Flow area Weight
Tube thick- (Note 2)
per tube, per linear ft.,
2
OD, in. BWG ness, in. ID, in. in Outside Inside lb steel Material Normally used
TABLE 7-3
Note: The Outside Packed Floating Head type closure is not commonly used in most
services. To determine the shell size of a Split Ring Floating Head, TEMA S type,
exchanger (most commonly used), read the shell I.D. which will give the number of
tubes required from the columns under Fixed Tube Sheet and add 2 inch to the read
I.D. to obtain the estimated shell I.D. For TEMA T type Floating Head, add
approximately 5 inches to the TEMA Fixed Tube Sheet type shell I.D. to obtain the
estimated shell I.D.
Shell I.D. Fixed Tube Sheet Outside Packed Floating Head U-Tube
(Incles) No. of passes No. of passes No. of passes
1 2 4 8 1 2 4 8 2 4 8
108.00 11377 11272 11132 10928 11196 11096 10968 10788 5524 5470 5382
120.00 14186 14068 13924 13720 13982 13888 13732 13516 6913 6846 6748
Shell I.D. Fixed Tube Sheet Outside Packed Floating Head U-Tube
(Incles) No. of passes No. of passes No. of passes
1 2 4 8 1 2 4 8 2 4 8
17.25 203 192 180 176 180 168 160 148 80 82 76
19.25 251 240 228 220 226 216 204 204 103 104 100
21.25 300 294 288 256 276 272 264 228 130 128 114
23.25 368 360 356 324 340 336 324 304 162 160 146
25.00 416 400 392 380 398 376 360 344 190 180 172
27.00 508 472 468 456 468 442 432 420 228 214 212
29.00 592 560 540 532 550 520 508 492 268 256 246
31.00 670 648 628 584 627 610 592 556 296 298 278
33.00 767 740 720 680 719 700 680 648 342 342 322
35.00 870 840 824 776 816 802 784 736 392 390 368
37.00 972 944 928 912 927 900 884 868 444 438 432
39.00 1086 1064 1036 1020 1036 1014 952 968 498 498 484
42.00 1257 1220 1212 1184 1204 1176 1148 1120 579 574 562
45.00 1452 1436 1412 1352 1396 1380 1360 1308 683 678 652
48.00 1666 1634 1608 1576 1602 1574 1540 1516 778 772 762
51.00 1880 1868 1848 1784 1814 1800 1768 1716 890 888 862
54.00 2125 2096 2064 2000 2051 2020 1988 1928 998 988 962
60.00 2608 2596 2568 2496 2532 2512 2468 2412 1246 1244 1208
64.00 2996 2982 2936 2868 2892 2884 2840 2776 1436 1424 1390
68.00 3375 3328 3288 3260 3270 3232 3188 3164 1605 1598 1588
72.00 3826 3752 3720 3676 3714 3648 3608 3560 1842 1806 1790
76.00 4270 4195 4152 4112 4170 4088 4052 4008 2060 2030 2004
80.00 4715 4664 4624 4528 4614 4560 4524 4424 2266 2260 2212
84.00 5223 5168 5120 5028 5109 5056 5000 4916 2512 2498 2454
90.00 5992 5964 5912 5816 5870 5844 5796 5680 2908 2900 2844
96.00 6852 6812 6780 6648 6720 6688 6636 6508 3331 3318 3256
108.00 8682 8618 8552 8412 8543 8476 8412 8288 4214 4198 4134
120.00 10782 10704 10636 10488 10634 10560 10942 10344 5252 5242 5164
8.0 ECONOMICS
Figure 8-3 shows such a plot for a revamped crude preheat train.
By analyzing the results from the plots as mentioned above, the
process engineer can then make changes to the exchanger train
configuration as deemed appropriate and recalculate the
temperature profile in the train for making new temperature driving
force and cost effectiveness plots.
A cost escalation factor of 1.35 based on the CPI index is then applied to
the value obtained from the curves to arrive at the estimated 1983 pricing.
It should be noted that process engineers are not required to provide
estimated exchanger cost. Cost data developed from this section is
intended only for internal use in process evaluations.
From Figure 8-4 (a) curve No. 2 for 300 psi design,
cost/ft2 - 11.25 x 1.35 = $15.20/ft2. Additive cost factor for
TEMA-A removable channel cover is 1.07.
9.0 NOMENCLATURE
Ao, Ai = Heat transfer surface, based on tube O.D. or I.D., respectively, ft2.
ho, hi = Shellside fluid film coefficient based on outside or inside tube area,
respectively, Btu/(hr-ft2-0F)
H = Enthalpy, Btu/lb.
t 2 - t1
P = , used with TEMA charts for correction factor F.
T 1 - t1
10.0 REFERENCES
2. Kern, D. Q., Process Heat Transfer, McGraw-Hill Book Co., Inc., New York,
1950, p. 843.
3. Kern, D. Q., Process Heat Transfer, McGraw-Hill Book Co., Inc., New York,
1950, p. 131.
8. Huang, F., and R. Elshout, Optimizing the Heat Recovery of Crude Units,
Chemical Engineering Progress, July 1976, p. 68.