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HEAT EXCHANGER SELECTION, SIZING AND TROUBLESHOOTING, Kolmetz

Handbook Of Process Equipment Design

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 Page : 1 of 139

Rev: 05
KLM Technology
Group
Practical Engineering Engineering Solutions Rev 01 January 2008
Rev 02 November 2010
Guidelines for Processing Plant
Solutions Rev 03 October 2014
Rev 04 January 2015
www.klmtechgroup.com Rev 05 November 2016

Co Author:
KLM Technology Group
Rev 01 A L Ling
P. O. Box 281 Kolmetz Handbook Rev 02 Viska Mulyandasari
Bandar Johor Bahru, Rev 03 Yurika Mandasari
80000 Johor Bahru, Johor, Of Process Equipment Design Rev 04 Mela Widiawati
West Malaysia Rev 05 Aprilia Jaya

HEAT EXCHANGER
Author / Editor:
SELECTION, SIZING AND
TROUBLESHOOTING Karl Kolmetz

(ENGINEERING DESIGN GUIDELINES)

TABLE OF CONTENT

INTRODUCTION

Scope 6

General Design Consideration 7

DEFINITIONS 26

NOMENCLATURE 29

THEORY

Selection of Exchanger Components 32

(A) Shell & Tube Heat Exchanger 32

(B) Tube Pattern 35

(C) Baffle 36

Basic Heat Balances 49

 Page 2 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Heat Exchanger without Phase Change 69

(A) Design Guide 69

(B) Step- by- Step Sizing Method 70

Condensation Process 73

Vaporization Process 73

Rating Heat Exchanger 77

APPLICATION

Example 1: Estimation Method -Shell & Tube Heat Exchanger 81

(No Change of Phase)

Example 2: Evaluation of Existing Operating Heat Exchanger Unit 91

Example 3: Condensation Process Calculation- Propane Refrigerator 99

Example 4: Rating an Ammonia Condenser 103

Example 5: Design a shell and tube exchanger for the following duty 106

Example 6: General Sizing of Some Type of Heat Exchanger 124

REFERENCES 122

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 3 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

LIST OF TABLE

Table 1: Typical Values of Fouling Coefficient and Resistances 21

Table 2: Guidelines for Placing the Fluid in Order of Priority 23

Table 3: Features of Shell and Tube Type Exchanger 24

Table 4: Determination of Number of Tube Passes Based on Shell ID. 25

Table 5: Supplements for Type Selection 34

Table 6: Common Tube Layout 36

Table 7: Tube Pattern Relationship 36

Table 8: Typical Heat Exchanger Parts and Connections 44

Table 9: Comparison of Classes R, C, & B 44

Table 10: Selection Guide Heat Exchanger Types 46

Table 11: Shell and Tube Exchanger Selection Guide (Cost Increase from Left to Right) 48

Table 12 : Minimum Temperature Approach for Heat Exchangers 51

Table 13 : Typical Metal Thermal Conductivities, km 54

Table 14 : Typical Heat Transfer Coefficients, U and Fouling Resistance, rf 55

Table 15 : Tube Dimensions 71

Table 16: The Common Tube Pitches Used 71

Table 17: Approximate Heat Transfer Coefficients for Shell-and-Tube Heat

Exchangers 79

Table 18: Pressure Drop Factor Ke for Difference Tubes 85

Table 19: Variable in Exchanger Performance 95

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 4 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Table 20: Base values for Use with Table 19 95

Table 21: Selected Heat-Transfer Fluids 103

Table 21: Summary of Heat-Exchanger Approach Temperature Differences and

Pressure Drops 104

Table 22 : Typical Overall Coefficient 108

Table 23 : Constants for Use in Equation 111

LIST OF FIGURE

Figure 1: U-tube Heat Exchanger 11

Figure 2: Straight Tube Heat Exchanger (one pass tube-side: countercurrent flow) 12

Figure 3: Straight Tube Heat Exchanger (two pass tube side) 13

Figure 4: Type 500 Shell & Tube Heat Exchangers 14

Figure 5: Plate Heat Exchanger 16

Figure 6: Block Welded Heat Exchanger (Plate Type) 17

Figure 7:Temperature profile of two fluid vs heat transfer. 22

Figure 8: Rear and Head Selection Chart 33

Figure 9: Tube Pattern 35

Figure 10: Type of heat exchanger baffles; a) Cut-segmental baffle; 37

b) Disc and doughnut baffle c) Orifice baffle

Figure 11: Baffles Cuts 38

Figure 12: Internal Shown of Shell and Tube Components. 39

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 5 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Figure 13: Nomenclature of Shell & Tube Exchanger 40

Figure 14: Type AES 41

Figure 15 : Type BEM 41

Figure 16: Type AEP, CFU 42

Figure 17: Type AKT, AJW 43

Figure 18 : Temperature Profile in Heat Exchanger: (a) Countercurrent and 50

(b) Co-current Exchangers

Figure 19a: LMTD Correction Factor For 1 Shell Pass, Even Number Of Tube Passes 56

Figure 19b: LMTD Correction Factor For 2 Shell Passes, 4 Or Multiple Of 57

4 Tube Passes

Figure 19c: LMTD Correction Factor For 3 Shell Passes, 6 Or More Even Number
Of Tube Passes 58

Figure 19d: LMTD Correction Factor For 4 Shell Passes, 8 Or Multiple Of

8 Tube Passes 59

Figure 19e: LMTD Correction Factor For 5 Shell Passes, 10 Or More Even Number
Of Tube Passes 60

Figure 19f: LMTD Correction Factor For 6 Shell Passes, 12 Or More Even Number
Of Tube Passes 61

Figure 19g: LMTD Correction Factor For 1 Shell Pass, 3 Tube Passes
(2 Counter & 1 Cocurrent) 62

Figure 19h: LMTD Correction Factor For Cross Flow Shell, 1 Tube Pass 63

Figure 19i: LMTD Correction Factor For 1 Divided Flow Shell Pass, 1 Tube Pass 64

Figure 19j: LMTD Correction Factor For 1 Divided Flow Shell Pass, Even Number
Of Tube Passes 65
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 6 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Figure 19k: LMTD Correction Factor For Split Flow Shell, 2 Tube Passes 66

Figure 19l: LMTD Correction Factor For Split Flow Shell, 4 Or Multiple Of 4
Tube Passes 67

Figure 19n: LMTD Correction Factor For Double Split Flow Shell, 2 Tube Passes 68

Figure 20: Kettle Reboiler 75

Figure 21: Recirculating ThermosyphonReboiler on Column Bottoms 76

Figure 22: Once-Through Reboiler With Bottoms Tray Feed 76

Figure 23 : Pump Around Reboiler on Column Bottoms 77

Figure 24: Normal Crossflow Fraction 87

Figure 25 : Baffle Spacing Correction 88

Figure 26: Friction Factor f or Heat Transfer ‘j’ Factor 89

Figure 27: Propane Condensing Curve 99

Figure 28: Temperature correction factor: one shell pass; two or more even
tube passes 109

Figure 29: Shell-bundle clearance 112

Figure 30: Tube-side heat-transfer factor 114

Figure 31: Tube-side friction factors 118

Figure 32: Friction factor for cross-flow tube banks (jf) 122

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 7 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

INTRODUCTION

Scope

This design guideline covers the selection, sizing methods and troubleshooting for heat
exchangers which are commonly used in typical industrial processes. It assists engineers,
operations personnel and maintenance personnel to understand the basic designs of
different types of heat exchangers, and increases their knowledge in selection and sizing. A
heat exchanger is a device for heat transfer from one medium to another.

The basic concept of a heat exchanger is based on the premise that the loss of heat on the
high temperature side is exactly the same as the heat gained in the low temperature side
after the heat and mass flows through the heat exchanger. Heat exchanger ‘simply’
exchanges the heat between those two sides; as a result, it is decreasing the temperature
of higher temperature side and increasing the temperature of lower temperature side. But
designing heat exchanger might be a challenge; it needs iteration for manual calculation.
Hence, a guideline to properly select and sizing is needed.

Many factors have to be considered in heat exchanger selection. Generally, suitability of

types of heat exchanger to be used in processing industrials is selected based on Industry
Standards. The standards divides heat exchanger into classes based on their application.
Comparison of each class in the standard is summarised in this guideline. Besides, various
type of heat exchanger with their best suitable application and limitation are also listed in
this guideline.

Selection might be done by referred to some valid standards or guideline, but

understanding the basic concept and theory behind heat exchanger is also important.
Furthermore, basic theories about heat transfer are also extremely needed to do heat
exchanger sizing. Hence, some theories are included in this guideline.

Selection and sizing are related each other; changing in heat exchanger component, such
as tube pattern and baffle, would affect the calculation. Some required data is commonly
pictured in a graph or listed in a table and they are attached in this guideline as well. To do
manual calculation, it is mentioned before, iteration is needed. This guideline gives some
approximation values as a ‘boundary’ for iteration. The step by step sizing method is also
explained in this guideline to simplify the calculation.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 8 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

In the application section, multiple cases examples are included to guide the reader by
using the step-by-step method to do heat exchanger sizing. A calculation spreadsheet is
also included as well to aid user more understand the calculation. This spreadsheet is also
helpful to make the calculation even easier.

General Considerations

Why Use Heat Exchangers

1. To cool process streams

a. Gasoline product going to storage is cooled to reduce loses because of its

vapor pressure.

b. General unit intercoolers remove the heat of reaction between reactors

c. Absorber intercoolers on gas concentration units remove the heat of

absorption and thereby increase the efficiency of the absorber

d. Fractionator condensers condense the overhead, part of which may be the

product and the other part of which may be reflux that is returned to the
column to help effect a separation

2. To heat process streams

a. Fractionator reboilers are used to add heat to fractionation column that effects
a separation.

b. Reactor charge heaters are used to heat the feed up to the reaction
temperature.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 9 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

3. To exchange heat between hot and cold process streams

a. Feed exchangers that is used to heat the reactor charge by exchanging heat
with the reactor effluent

b. Fractionator feed-bottoms exchanger that is used to heat the feed by

exchanging heat with the bottoms

Heat Exchanger Type

Heat transfer equipment is usually specified both by type of construction and by service.

A heat exchanger is a specialized device that assists in the transfer of heat from one fluid
to the other. In some cases, a solid wall may separate the fluids and prevent them from
mixing. In other designs, the fluids may be in direct contact with each other. In the most
efficient heat exchangers, the surface area of the wall between the fluids is maximized
while simultaneously minimizing the fluid flow resistance. Fins or corrugations are
sometimes used with the wall in order to increase the surface area and to induce
turbulence.

In heat exchanger design, there are three types of flow arrangements: counter-flow,
parallel-flow, and cross-flow. In the counter-flow heat exchanger, both fluids entered the
exchanger from opposite sides. In the parallel-flow heat exchanger, the fluids come in from
the same end and move parallel to each other as they flow to the other side. The cross-flow
heat exchanger moves the fluids in a perpendicular fashion. Compare to other flow
arrangements counter flow is the most efficient design because it transfers the greatest
amount of heat.

There are two major different designs of heat exchangers: shell and tube, and plate heat
exchanger. The most typical type of heat exchanger is the shell and tube design. This heat
exchanger can be design with bare tube or finned tubes. One of the fluids runs through the
tubes while the other fluid runs over them, causing it to be heated or cooled. In the plate
heat exchanger, the fluid flows through baffles. This causes the fluids to be separated by
plates with a large surface area. This type of heat exchanger is typically more efficient than
the shell and tube design.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 10 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

(A) Shell & Tube Exchanger

A shell and tube heat exchanger is a class of heat exchanger designs. It is the most
common type of heat exchanger in oil refineries and other large chemical processes, and is
suited for higher-pressure applications. It consists of a tube bundle enclosed in a cylindrical
casing called a shell. One fluid runs through the tubes, and another fluid flows over the
tubes (through the shell) to transfer heat between the two fluids.

Two fluids, of different starting temperatures, flow through the heat exchanger. One flows
through the tubes (the tube side) and the other flows outside the tubes but inside the shell
(the shell side). Heat is transferred from one fluid to the other through the tube walls, either
from tube side to shell side or vice versa. The fluids can be either liquids or gases on either
the shell or the tube side. In order to transfer heat efficiently, a large heat transfer area
should be used, so there are many tubes. In this way, waste heat can be put to use. This is
a great way to conserve energy.

Typically, the ends of each tube are connected to plenums through holes in tubesheets.
The tubes may be straight or bent in the shape of a U, called U-tubes. Most shell-and-tube
heat exchangers are either 1, 2, or 4 pass designs on the tube side. This refers to the
number of times the fluid in the tubes passes through the fluid in the shell. In a single pass
heat exchanger, the fluid goes in one end of each tube and out the other.

There are two basic types of shell-and-tube exchangers. The first is the fixed tube sheet
unit, in which both tube sheets are fastened to the shell and the tube bundle is not
removable. The second type of shell-and-tube unit has one restrained tube sheet, called
the stationary tube sheet, located at the channel end. Differential expansion problems are
avoided by use of a freely riding floating tube sheet at the other end or the use of U tubes.
This design may be used for single or multiple pass exchangers. The tube bundle is
removable from the channel end, for maintenance and mechanical cleaning.

There are often baffles directing flow through the shell side so the fluid does not take a
short cut through the shell side leaving ineffective low flow volumes.

Counter current heat exchangers are most efficient because they allow the highest log
mean temperature difference between the hot and cold streams. Many companies however
do not use single pass heat exchangers because they can break easily in addition to being

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 11 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

more expensive to build. Often multiple heat exchangers can be used to simulate the
counter current flow of a single large exchanger.

shell-side
fluid out

baffle shell tube sheet

outlet plenum

out

in
tube-side
fluid

shell side inlet plenum

baffle
tube bundle
with U-tubes shell-side
fluid out

Figure 1: U-tube Heat Exchanger

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 12 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

tube bundle shell-side

with straight fluid in
tube sheet tubes tube sheet
shell

outlet plenum
inlet plenum

baffle
shell-side
fluid out tube-side
tube-side
fluid out
fluid in

Figure 2: Straight Tube Heat Exchanger (One Pass Tube-Side: Countercurrent Flow)

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 13 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

tube-side
tube bundle shell-side fluid in
with straight fluid in
tube sheet tubes
shell

plenum
inlet
plenum
outlet
tube sheet
baffle
shell-side
fluid out tube-side
fluid out

Figure 3: Straight Tube Heat Exchanger (Two Pass Tube Side)

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 14 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Figure 4: Type 500 Shell & Tube Heat Exchangers

(B) Plate Heat Exchangers

Plate and frame heat exchanger for general refinery service can be referred as gasketed
plate heat exchangers. The plate heat exchanger consists of a frame, which consists of a
head, follower, column, carrying bar, guiding bar, and a number of clamping bolts. In
between head and follower a varying number of pressed plates are clamped together. Each
plate is supplied with a gasket, so that the plates form a closed system of parallel flow
channels, through which the media flow alternatively at every second interval.

The gaskets are glued on the plates, securing tightness between media and the
atmosphere. Between the different media there are double gaskets, which have
intermediate drain areas, meaning that mixing of the two media is impossible. Every
second plate in the stack has to turn 180°, so that the plates form a closed system of
parallel flow channels, through which the media flow alternatively at every second interval.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 15 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

The advantage of the gasketed plate heat exchanger:

(i) High thermal efficiency due to high film efficiency of heat transfer for both fluids, no
bypassing and leakage streams, and counter-current operation.

(ii) Plate design is feasible with size, chevrons angles and pass arrangements.

(iii) Easy maintenance that the plate can be easily disassembled for cleaning.

(iv) The plates of the unit can be rearranged, added or removed from the plate rack to
suit for difference of service condition.

(v) Have very wide range of total surface area up to 15,000 ft2.

(vi)Low fouling is encountered due to high turbulence create by plate and the fluid low
residence in plate.

The disadvantage,

(i) Have limitations in service temperature and pressure. Maximum service temperature
is 450oF and pressure is 335 psig.

(ii) The gaskets impose restrictions on the nature of the fluids which can be handled.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 16 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Figure 5: Plate Heat Exchanger

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 17 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Figure 6: Welded Heat Exchanger (Plate Type)

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 18 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Design Consideration

Shell and tube exchanger: general design considerations

- Fluid allocation : shell or tubes

Where no phase change occurs, the following factors determine the allocation of the
fluid streams to the shell or tubes.

*corrosion. The more corrosive fluid should be allocated to the tube side. This will
reduce the cost of expensive alloy or clad components.

*Fouling. The fluid that has the greatest tendency to foul the heat-transfer surfaces
should be placed in the tubes. This gives better control over the design fluid velocity,
and the higher allowable velocity in the tubes will reduce fouling. Also, the tubes will
be easier to clean.

*Fluid temperatures. If the temperature are high enough to require the use of special
alloys, placing the higher temperature fluid in the tubes will reduce the shell surface
temperatures, and hence the need for lagging to reduce heat loss or for safety
reasons.

*Operating pressures. The higher pressure stream should be allocated to the tube
side. High-pressure tube will be cheaper than a high-pressure shell. The required
tube thickness is less for high internal pressure than high external pressure and an
expensive high-pressure shell may be avoided.

*Pressure drop. For the same pressure drop, higher heat-transfer coefficients will be
obtained on the tube side than the shell side, and fluid with the lowest allowable
pressure drop should be allocated to the tube side.

*Viscosity. Generally, a higher heat-transfer coefficient will be obtained by allocating

the more viscous material to the shell side, providing the flow is turbulent. The
critical Reynolds number for turbulent flow in the shell is in the region of 200. If
turbulent flow cannot be achieved in the shell, it is better to place the fluid in the
tubes, as the tube-side heat transfer coefficient can be predicted with more certainly.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 19 of 139
Kolmetz Handbook
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Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
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www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

*Stream flow rates. Allocating the fluids with the lowest flow rate to the shell side will
normally give the most economical design.

- Shell and tube fluid velocities

*liquids – tube side, process fluids; 1 to 2 m/s, maximum 4 m/s if required to reduce
fouling; water: 1.5 to 2.5 m/s.

Shell side: 0.3 to 1 m/s.

*vapors – for vapors, the velocity used will depend on the operating pressure and
fluid density; the lower values in the ranges given below will apply to high molecular
weight materials.

 Vacuum 50 to 70 m/s
 Atmospheric pressure 10 to 30 m/s
 High pressure 5 to 10 m/s

- Stream temperatures

- Pressure drop

-
*Liquids
Viscosity Allowable Pressure Drop

<1mN s/m2 35 kN/m2

1 to 10 mN s/m2 50 – 70 kN/m2

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 20 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

*Gas and Vapors

High vacuum 0.4-0.8 kN/m2

Medium vacuum 0.1 x absolute pressure

1 to 2 bar 0.5 x system gauge pressure

Above 10 bar 0.1 x system gauge pressure

- Fluid Physical Properties

Alternatively, the method suggested by Frank (1978) can be used :

(A) All Heat Exchanger Types

(a) Operating temperature

The operating temperatures of the exchanger are usually set by process conditions.
However, in certain cases, the exchanger designer will establish the operating
temperatures. In a typical refinery or petrochemical plant, exchangers may be
operating at temperatures as high as 1000°F or as low as -200°F. These limits are
dictated by material considerations, safety, economics and ASME Code
requirements.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 21 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
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Solutions
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(ENGINEERING DESIGN GUIDELINE)

(b) Effective temperature difference

The driving force for heat transfer is the “effective temperature difference," LMTD,
between the hot and cold fluids. This temperature difference is calculated from the
counter-current log mean temperature difference with a correction factor applied to
account for the actual flow arrangement.

Temperature approach

Temperature approach is the difference of the hot side and cold side fluid
temperatures at any point within a given exchanger. A temperature cross indicates a
negative driving force for heat transfer between the fluids. It requires either a large
area for heat transfer or high fluid velocities to increase the overall heat transfer
coefficient. If outlet temperatures form a cross in a multi-tube pass heat exchanger,
a lower than desirable LMTD correction factor will occur. A simple way to avoid this
is to use more exchanger shells in series.

(c) Fouling factors

The increased resistance to both heat transfer and fluid flow caused by deposits on
a heat transfer surface is called fouling.

Fouling works as an insulating layer on the heat transfer surface, reducing heat
transfer efficiency (reduced duty) or decreasing available flow area (reduced
throughput). The increased resistance to heat transfer is represented by a quantity
referred to as the fouling thermal resistance, which is added to the total thermal
resistance. The values of fouling thermal resistance have generally been observed
to increase with time. To account for the effect of fouling on pressure drop requires
an estimate of the fouling layer thickness.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 22 of 139
Kolmetz Handbook
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Group
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Table 1: Typical Values of Fouling Coefficient and Resistances

Fluid Coefficient (W.m-2.C-1) Resistance (m2.oC.W-1)
River water 3000-12,000 0.0003-0.0001
Sea water 1000-3000 0.001-0.0003
Cooling water (towers) 3000-6000 0.0003-0.00017
Towns water (soft) 3000-5000 0.0003-0.0002
Towns water (hard) 1000-2000 0.001-0.0005
Steam condensate 1500-5000 0.00067-0.0002
Steam (oil free) 4000-10,000 0.0025-0.0001
Steam (oil traces) 2000-5000 0.0005-0.0002
Refrigerated brine 3000-5000 0.0003-0.0002
Air and industrial gases 5000-10,000 0.0002-0.0001
Flue gases 2000-5000 0.0005-0.0002
Organic vapors 5000 0.0002
Organics liquids 5000 0.0002
Light hydrocarbons 5000 0.0002
Heavy hydrocarbons 2000 0.0005
Boiling organics 2500 0.0004
Condensing organics 5000 0.0002
Heat transfer fluids 5000 0.0002
Aqueous salt solutions 3000-5000 0.0003-0.0002

(d) Pressure drop

The pressure drop through an exchanger is made up of three losses: the frictional
loss due to flow, the losses due to changes in direction of flow and losses due to
expansion and contraction into and out of nozzles and tubes. In some exchangers, a
change in the vertical elevation of the fluid as it passes through the exchanger may
cause a hydrostatic pressure loss or gain.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 23 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

(B) Shell and Tube Exchangers

(a) Determination of number of shells based on graphical method as following.

T1 Tm2

t2 Tmt

tm2
T2
tmt
T t1

Figure 7: Temperature Profile of Two Fluid vs Heat Transfer.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 24 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

(b) Tube Selection

 Type
 Length
 Diameter and wall thickness
 Ferrules

Table 2: Guidelines for Placing the Fluid in Order of Priority

Tube-side fluid Shell-side fluid
Corrosive fluid Condensing vapor (unless
corrosive)
Cooling water Fluid with large temperature
difference (>40oC)
Fouling fluid
Less viscous fluid
High-pressure steam
Hotter fluid

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 25 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Table 3:Features of Shell and Tube Type Exchanger

Shell and Typical Advantages Limitations

Tube code
Exchanger
Fixed tube BEM, Provides maximum Shell side / outside of the tubes
sheet AEM, NEN heat transfer area for a are inaccessible for mechanical
given shell and tube cleaning.
diameter.
No provision to allow for
Provides for single and differential thermal expansion
multiple tube passes to developed between the tube and
assure proper velocity. the shell side. This can be taken
care by providing expansion joint
Less costly than on the shell side.
removable bundle
designs.
Floating head AEW, Floating tube sheet To provide the floating-head
BEW, allows for differential cover it is necessary to bolt it to
BEP, AEP, thermal expansion the tube sheet. The bolt circle
AES, BES between the shell and requires the use of space where it
tube bundle. would be possible to place a
large number of tubes.
Both the tube bundle
and the shell side can Tubes cannot expand
be inspected and independently so that huge
cleaned mechanically. thermal shock applications should
be avoided.

Packing materials produce limits

on design pressure and
temperature.
U-tube BEU, AEU U-tube design allows Because of U-bend some tubes
for differential thermal are amitted at the centre of the
expansion between the tube bundle.
These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 26 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

shell and the tube

bundle as well as for Because of U-bend, tubes can be
individual tubes. cleaned only by chemical
methods.
Both the tube bundle
and the shell side can Due to U-tube nesting, individual
be inspected and tube is difficult to replace.
cleaned mechanically.
No single tubes pass or true
Less costly than countercurrent flow is possible.
floating head or
packed floating head Tube wall thickness at the U-
designs. bend is thinner than at straight
portion of the tubes.

Draining of tube circuit is difficult

when positioned with the vertical
position with the head side
upward.

Table 4: Determination of Number of Tube Passes Based on Shell ID.

Shell ID Recommended Maximum
In Mm Number of Tube Passes

<10 < 254 4

10 - < 20 254 - < 508 6
20 - < 30 508 - < 762 8
30 - < 40 762 - < 1016 10
40 - < 50 1016 - < 1270 12
50 - < 60 1270 - < 1524 14

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 27 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
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HEAT EXCHANGER
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Solutions
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(ENGINEERING DESIGN GUIDELINE)

(c) Tube Site Flow

Whichever fluid appears higher on the following list will ordinarily be passed through
the tubes:

(i). Cooling water.

(ii). Corrosive fluid or a fluid likely to deposit coke, sediment or other solids.
(iii). Fouling fluid, which the fluid can cause fouling.
(iv). Fluid with the less viscosity.
(v). The fluid under higher pressure
(vi) The hotter fluid.
(vii) Less volume fluid.

(d) Fluid velocity –

Liquid - Tube side: 3 – 7 ft/s and maximum is 13 ft/s if need to reduce fouling;
Water is 5 – 8 ft/s.
Shell side: 1 – 3 ft/s
Vapour – Vacuum: 164 – 230ft/s; Atmospheric: 33 - 98ft/s; High pressure:16 – 33ft/s

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 28 of 139
Kolmetz Handbook
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
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(ENGINEERING DESIGN GUIDELINE)

DEFINITION

Baffle- A device to direct the shell side fluid across the tubes for optimum heat transfer by
difference of baffle cut %.

Condenser - A vessel use to change a fluid stream from the vapor state to the liquid state
by removing the heat of vaporization. The fluid stream can be a pure component or a
mixture of components. Condensation may occur on the shell side or the tube side of an
exchanger oriented vertically or horizontally.

Cooler - Commonly is an insulated box, used to keep food or drink cool. Ice cubes which
are very cold are most commonly placed in it to make the things inside stay cool. Ice packs
are sometimes used, as they either contain the melting water inside, or have a gel sealed
inside that also stays cold longer than plain water.

Expansion Joint “J” Factor- Is the ratio of the spring rate of the expansion joint to the
sum of the axial spring rate of the shell and the spring rate of the expansion joint.

Fouling - The increased resistance to both heat transfer and fluid flow caused by deposits
on a heat transfer surface. Fouling works as an insulating layer on the heat transfer
surface, reducing heat transfer efficiency (reduced duty) or decreasing available flow area
(reduced throughput). The increased resistance to heat transfer is represented by a
quantity referred to as the fouling thermal resistance, which is added to the total thermal
resistance. The values of fouling thermal resistance have generally been observed to
increase with time. To account for the effect of fouling on pressure drop requires an
estimate of the fouling layer thickness.

Heater -A heater is any object that emits heat or causes another body to achieve a higher
temperature. In a household or domestic setting, heaters are commonly used to generate
heating

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 29 of 139
Kolmetz Handbook
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(ENGINEERING DESIGN GUIDELINE)

Knock-Back Condenser- An apparatus and method useful for partially condensing vapor
in the upper section of a fractionation tower to separate and remove a lighter gaseous
fraction from a condensed liquid component, such as nitrogen from natural gas. A
downflow, knockback condenser is disclosed that utilizes a vapor riser to introduce a flow of
vapor into a headspace above a vertical tubular heat exchanger, thereby establishing a
downflow of condensed liquid and a lighter gaseous fraction through the heat exchange
tubes.

Nozzle – Nozzles are the pipe sections use to connect to the heat exchanger headers to
the piping.

Pumparound Coolers- Pumparound coolers cool a side stream from an intermediate tray
of a distillation column. The side stream or pumparound, after it has been cooled, is
returned to another tray in the distillation column. A part of the pumparound may be drawn
as side stream product.

Reboiler - are heat exchangers typically used to provide heat to the bottom of industrial
distillation columns. They boil the liquid from the bottom of a distillation column to generate
vapors which are returned to the column to drive the distillation separation.

Steam Generator - a device used to boil water to create steam. It may refer to Boiler, a
closed vessel in which water is heated under pressure ; Steam generator (nuclear power),
a heat exchanger in a pressurized water reactor equipped nuclear power plant; Steam
generator (railroad), a device used in trains to provide heat to passenger cars.

Superheater- is a device in a steam engine that heats the steam generated by the boiler
again, increasing its thermal energy and decreasing the likelihood that it will condense
inside the engine. Superheaters increase the efficiency of the steam engine, and were
widely adopted. Steam which has been superheated is logically known as superheated
steam; non-superheated steam is called saturated steam or wet steam. Superheaters were
applied to steam locomotives in quantity from the early 20th century, to most steam
vehicles, and to stationary steam engines including power stations.

Support Plate- Is a device to support the bundle or to reduce unsupported tube span
without consideration for heat transfer.

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 30 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
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(ENGINEERING DESIGN GUIDELINE)

Tubesheet - Is the barrier between the shell and tube fluids, and where it is essential for
safety or process reasons to prevent any possibility of intermixing due to leakage at the
tube sheet joint.

Vaporizer -A vaporizer is an exchanger that converts liquid into vapor. This term is
sometimes limited to units handling liquids other than water.

NOMENCLATURE

A Effective surface area (outside), ft2

a  Tube row spacing factor, dimensionless
Ao Surface area outside (tube), ft2
Ai Surface area inside (tube), ft2
As   Effective heat transfer area per shell, ft2
AT Single tube outside surface area per unit length ft2/ft
Cp Fluid specific heat, Btu/IboF
CMTD Corrected Mean Temperature Difference
Di Diameter inside (tube), in
DN   Nominal nozzle I.D., in.
Do Diameter outside (tube), in
DOTL   Diameter of bundle outer tube limit, in.
DS Shell I.D., in.
DSNI   Shell side inlet nozzle I.D., in.
DSNO   Shell side outlet nozzle I.D., in.
DTNI    Tube side inlet nozzle I.D., in.
DTNO   Tube side outlet nozzle I.D., in.
d OD of root diameter of integrally finned, in
f  Non-isothermal friction factor, dimensionless
F2 LMTD correction factor
Fs  Shell side pressure drop correction factor, dimensionless
GTTD Greatest Terminal Temperature Difference, oF
HF    Shell side friction term, dimensionless
HM   Shell side momentum term, dimensionless

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 31 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
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(ENGINEERING DESIGN GUIDELINE)

ho Film coefficient outside, Btu/(hr.ft2.oF)

hi Film coefficient inside, Btu/(hr.ft2.oF)
j  Stanton Number type heat transfer factor, dimensionless
Ke  Tube side pressure drop coefficient, dimensionless
k  Thermal conductivity of fluid, Btu/hr-ft2-F/ft
km Thermal conductivity of metal, Btu/[hr.ft2.oF)/ft]
L  Tube length, ft
l Tube wall thickness, in
LBCC Central baffle pitch, in.
LI Tube flow length, in.
LMTD Log Mean Temperature Difference, oF
LTTD Least Terminal Temperature Difference, oF
Le  Effective tube length, ft
N  Number of tube passes
Nf Number of fins per inch
Np Number of shells in parallel
Ns Number of shells in series
NT Total number of shells
NTP  Number of tube passes per shell
NTT Number of tubes in a bundle
n nth zone value
nr Baffle spacing to bundle diameter ratio, dimensionless
p  Baffle flow factor, dimensionless
PR   Tube pitch ratio, dimensionless
PT   Tube pitch, in.
 Pe Tube entrance, expansion, and turnaround pressure drop, psi
 Pexch Total nozzle to nozzle shell side pressure drop, psi
 Pn Tube side nozzle pressure drop, psi
 Ps Shell side pressure drop (excluding nozzles), psi
 Psn Shell side nozzle pressure drop, psi
∆Pt Tube side frictional pressure drop, psi
(∆Pt)nn Total tube side nozzle pressure drop, psi

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 32 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
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HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
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www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Q Heat transferred, Btu/hr

R Sum of resistances, (hr.ft2.oF)/ Btu
Rc   Total resistance (clean) to heat transfer, (hr-ft2-F)/Btu
Re    Reynolds Number, dimensionless
Rext   Shell side total flow Reynolds Number, dimensionless
Rexh Cross flow Reynolds number for heat transfer, dimensionless
Rexp Cross flow Reynolds Number for pressure drop, dimensionless
rfo Fouling resistance outside (shell), (hr.ft2. oF)/Btu
rI Inside fouling factor to inside surface area, hr-ft2-°F/Btu
rfi Fouling resistance inside (tube) referred to outside surface area,,
((hr.ft2. oF)/Btu)
rw Metal resistance for tube, (hr.ft2. oF)/Btu
SC   Baffle spacing correction factor, dimensionless
STT Tube sheet material allowable stress at design temperature, lb/in2.
ΔT Fluid temperature change, oF
TSb Bulk temperature of shell side fluid, F
TTb Bulk temperature of tube side fluid, F
TTT   Total tube sheet thickness, ft
U Overall heat transfer coefficient, Btu/hroF.ft2
Uc Clean coefficient, Btu/hroF.ft2
UD Calculated overall fouled coefficient of heat transfer, Btu/hr-ft2-F
Uo Overall duty coefficient of heat transfer, Btu/hr-ft2-F
Vn Tube side average nozzle fluid velocity, ft/sec
Vt Fluid velocity in tubes, ft/sec
W Fluid flow rate, Ib/hr
Ws Shell side mass rate per shell, lb/hr
w Fin height, in
WTD Weighted temperature difference, oF

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.
 Page 33 of 139
Kolmetz Handbook
KLM Technology Of Process Equipment Design Rev: 05
Group
Practical Engineering
HEAT EXCHANGER
Guidelines for Processing Plant SELECTION, SIZING AND
Solutions
TROUBLESHOOTING November 2016
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINE)

Greek letters

λ Latent heat of specific fluid, Btu/Ib

 Viscosity correction for wall temperature, dimensionless
b Viscosity at bulk temperature, centipoise
W Viscosity at wall temperature, centipoise
 Baffle correction factor, dimensionless
    Density, lb/ft3

These design guidelines are believed to be as accurate as possible, but are very general and not for specific design cases. They were
designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for
the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours
that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with
experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any
way communicated or made accessible to third parties without our written consent.

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