Step 1: Fluid allocation shell and tube side

Sr. # Service Allocation

1 Hazardous service
2 Low available Pressure drop: shell
3 Highly viscous Fluid: shell

4 Fouling Service: tubes

shell, exception of u tubes
5 Corrosive Fluid: tubes
6 Dirty and fluids with suspended solids: tubes
shell, use square pitch
7 Less heat transfer coefficient fluid: shell
8 Fluid Phase Shell
Tubes, Condensing fluid
9 Cooling water Tubes

10 Operating Pressure: tubes

shell, if smaller shell dia
11 Operating Temperature: tubes

Step 2: Select Tube Sheet type

1 Fixed tube sheet L,M,N
2 U-Tube Bundle U
3 Floating head S,T,W,P

Step 3: Selection of Shell type

1 Simple shell E
2 longitudinal baffle F
3 single split flow G
4 double split flow H
5 Divided flow J
6 kettle type K
7 Cross flow X

Step 4: Front Head Selection

1 head cover removeable A
2 bonnet type B
3 tube sheet integral with head C
 tube sheet integral with head/high
4 D
pressure closure
5 tube sheet integral with shell and head N

Step 5: Rear Head Selection

1 L
2 Fixed tube sheet M
3 N
4 U-Tube Bundle U
5 S / Internally floating
6 T / Internally floating
Floating head
7 W / Externally floating
8 P / Externally floating

Exchanger designing
make a model on aspen hysys as simple end point

Notes

nozzle and the end of the shell is

Selection of multiple nozzels in X shell greater than 2.5 times the shell
diameter
thermal expansion to be studied by mechanical and a form is present JGC
 Designing a Heat Exchanger

Reasoning
Placed properly bolted and gasketed or welded
Place in shell
Viscous fluids show high pressure drop, so should be placed in shell side.
Less heat transfer coefficient, better to place in shell baffles will improve heat transfer due to turbulance
High viscosity causes baffle bypassing, which can hurt heat transfer
shell side cleaning is difficult than tubes/place more fouling media in tubes
if exchanger has a u tube bundle, place fouling service in shell
corrosion causes metal reduction so replacement will be required after some time, place them in tubes to reduce the impac
place dirty fluids in tube as shell side cleaning is dificult as compared to tube.
if due to other considerations u are supposed to place in shell, use square pitch
better to place in shell baffles will improve heat transfer due to turbulance
if boiling/vaporizing fluid then place it in shell
if it is a condensing service, place in tube side.
low flow velocity can induce fouling due to sedimentation possibility
high velocity can cause errosion corrosion issue.
fluid to be placed in tubes to minimize stagnant areas
high pressure service, requires high thickness support, thick shell is a costly choice as compared to tubes, so place them in tu
high pressure fluid can be placed in shell, if it reduces the shell dia.
at higher temperatures, metal strength is lowered due to thermal stresses, so higher thickness will be required as in high pr

if shell side fluid is clean, most economical type, can acccount thermal expansion with expansion bellows.
if tube side service is clean and differential temperature is wide, expensive then fixed tube sheet but economical than floati
if large thermal expansion is required with tube side mechanical cleaning, then floating head type is used.

if available pressure drop is high

If multi shell pass required/save cost by using F/ max ΔT per shell is 121 C/If pure counter flow is required (two tube pass ar
close approach temperature is required/ flow rate permits the use of one half of the shell

drastically low ΔP < 0.2 kPa/single phase service/bypassing issue/low heat transfer rate, horizontal thermosyphon reboilers
low available pressure drop/thermal expansion/phase change i.e., condensation/vaporizing
service with phase change with lowest pressure drop/K shells are expensive for high pressure vaporization due to shell diam
disengagement.
Shell side condensers and gas cooler/low pressure

tube side design pressure less than 10 bar and frequent cleaning is expected.
less chances of leakage/less costly / fouling resistance at or below 0.00035m-2K/W
if tube side service is above 100 bar, cleaning and tube are accesible/ leakage prevention
if tube side pressure is above 150 bar

Difficult to maintain and replace/ very high pressure service / reduced tube sheet thickness / less no. of high pressure retain

when A type front head is used and odd number of tube passes are there
less chances of leakage/less costly / fouling resistance at or below 0.00035m-2K/W
Difficult to maintain and replace/ very high pressure service / reduced tube sheet thickness / less no. of high pressure retain
leakage prevention even tube passes / pure counter flow not possible/ tightest bundle to shell clearance / unlimited therma
shell nominal dia should be more than DN 250 / most expensive / smaller shell to bundle clearances / Unlimited thermal e
frequent cleaning / cheaper than S / largest bundle to shell clearance / Unlimited thermal expansion
low pressure nonhazardous fluids / large bundle to shell clearances / Unlimited thermal expansion / cheapest floating head
low pressure nonhazardous fluids / large bundle to shell clearances / Limited thermal expansion
Δ
(a) shell side fouling resistance is under 0.00035 m 2 -K/W(0.0004 m 2 -h-C /kcal)
(b) tube side fouling resistance is under 0.00035 m 2 -K/W (0.0004 m 2 -h-C /kcal)
(c) Leakage should be prevented.
(d) tube side design pressure is higher than 3920 kPaG(40 Kg/cm 2G) and shell I.D. is 350mm or g
m 2 -h-C /kcal)
m 2 -h-C /kcal)

G) and shell I.D. is 350mm or greater.