ADDENDUM 4.

01

SHORTCUT HEAT EXCHANGER

DESIGN PROCEDURE

ADDENDUM 4.01
SECTION 4 - PROCESS DESIGN COURSE
HEAT EXCHANGER DESIGN
A SHORTCUT PROCEDURE FOR APPROXIMATE EVALUATION OF SHELL AND TUBE EXCHANGERS WITH NO CHANGE OF PHASE
IMPORTANT NOTE AND WARNING:

This procedure must not be used for the definitive design of heat exchangers. It is a shortcut
technique which makes many simplifying assumptions, especially with regards to shell-side
calculations
The Reynolds Number used in this Addendum is dimensional.
INDEX
DESCRIPTIVE MATERIAL
PAGE
1. LMTD & Caloric Temperature/Properties
2. Shell Side, Tube Side Flowrates
3. Fouling
4. Tube Side Calculations
5. Shell Side Calculations
6. Duty & Clean Coefficients
7. Design Temperature of Tube Sheet
8. Calculation Form
9. Nomenclature Summary
TABLE
1.01 General Design Constants
1.02 Exchanger Tube Data
1.03 Thermal Conductivities of Metals
1.04 Typical Fouling Factors
1.05 Typical Overall Coefficients
FIGURES
1.01-1.03 Fn Factors
2.01-2.02 Tube Side Correlations
3.01-3.02 Shell Side Correlations
4.01-4.02 Thermal Function K (Pr)1/3

3.58

SHORTCUT PROCEDURE
SCOPE
The following subsection presents an approximate procedure for evaluating
shell and tube exchangers in which there is no change of phase, (i.e., vapour /
vapour, vapour/liquid or liquid/liquid exchangers). The actual calculations can
be made on the calculation form, which starts on page 8. Each Step of the
procedure is explained in the following paragraphs.

3.59

SHORTCUT PROCEDURE
DETAILED PROCEDURE
1. Terminal Conditions and Effective Log Mean Temperature Difference
a. Determine the following temperatures
Inlet temperature of fluid being cooled, T 1
Outlet temperature of fluid being cooled, T2
Inlet temperature of fluid being heated, t 1
Outlet temperature of fluid being heated, t2
b. Determine the log mean temperature difference, tm

tm = (T1 - t2) - (T2 - t1)

ln (T1 - t2)
(T2 - t1)
c. From Figure 1.01 - 1.03, determine the minimum number of shells required
for a temperature correction factor (Fn) of at least 0.8000.
d. Determine the effective log mean temperature differences,

te = Fntm

te

3.59

SHORTCUT PROCEDURE (Continued)

2. Caloric Temperatures
a. Decide which fluid to pass through the tubes and which through the shell
b. Calculate the caloric temperatures.
For the fluid being heated, tt or ts = 0.4(t2 - t1)+t1
For the fluid being cooled, ts or tt = 0.4(T1 - T2)+T2
3. Caloric Properties of Fluids
a. Tube Side of Exchanger
1. At the caloric temperature tt, determine the following tube side fluid
properties:
For water:density, m
For hydrocarbon liquids or vapors: density, m; viscosity, z
For other fluids: density, m; viscosity, z; specific heat, c; and thermal
conductivity, k
b. Shell Side of Exchanger
1. At the caloric temperature, determine the density, m of the shell side fluid.

3.60

SHORTCUT PROCEDURE (Continued)

4. Shell Side and Tube Side Flow Rates
The values of the respective flow rates in lb/hr will normally be determined during the heat and
material balance calculations
5. Fouling Factors
a. Decide the tube side fouling factor r i (See Table 1.04)
b. Decide the shell side fouling factor r o (See Table 1.04)
6. Iteration, Tube Side
(1) The heat duty for the exchanger will normally be determined during the heat and
material balance calculations.
(2) Assume U, the over-all coefficient (See Table 1.05)
(3) Calculate total area
A = Q / U te
(4) Calculate the area per shell.
As = A / Ns
If necessary, the number of shells should be increased to meet the maximum
shell size limitations (typically 48). This will require recalculating F n te, A, As
(5) Decide the tube metal and determine tube thermal conductivity, k w (See Table 1.03).

3.61

SHORTCUT PROCEDURE (Continued)

(6) Choose the tube length, diameter, wall thickness, pitch, and layout (See Tables 1.01 and 1.02).
(7) Determine the number of tubes as follows:

NT =

3.82 As
(L - 0.5) do

(8) Estimate Np, the even number of tube passes per bundle which will give a reasonable tubeside velocity (3-20 fps).
(9) Calculate the linear velocity in the tubes and in the nozzles:
(dN = Nozzle ID) V

NpM

; VN =

19.6mNTdi

2
19.6md N

(10) Tube side pressure drop and heat transfer coefficient (for water).
a. Tube side heat transfer coefficient, hio for water from approximately 80F to 180F.

1
Rio

hio = 368 (Vdi)0.7

do

tt

0.26

100

3.62

SHORTCUT PROCEDURE (Continued)

b. Total tube side pressure drop, Pt, for water at approximately 100F.

Pt = 0.020FtNsNp

V2+0.158L
+ PN

V1.73
di1.27

For PN, See Step 15 (nozzle pressure drop).

(11) For fluids other than water:
a. Calculate the tube side mass velocity, G
G = mV
b. Calculate tube side Reynolds Number, N re (dimensional)

NRe = diG
z
Note: At this point, check for a transition problem by calculating N Re using
fluid
properties at inlet (or outlet) conditions. An Exchanger design is not valid if the type of flow
conditions changes from viscous to turbulent (or vice-versa) within the unit.
(12) From Figure 2.01 determine the tube side pressure drop correlation factor, Y tp.

3.63

SHORTCUT PROCEDURE (Continued)

(13) Calculate the tube side velocity head and the nozzle velocity head.
mV2N in the nozzles ; mV2 in the tubes
9270
9270
(14) Calculate Ptf, the frictional pressure drop per tube pass.
Ptf = Ytp L
di

mV2
9720

Zw
z

0.14 or 0.25

The exponent 0.14 is for turbulent flow (N Re < 30); 0.25 is for streamline flow (N Re< 30).
(15) Calculate the pressure drop per tube pass due to turns, Ptr, and the nozzle pressure
drop, PN.
Pt = 3

mV2
9270

; PN= 2

mV2
9270

(two nozzles)

3.64

SHORTCUT PROCEDURE (Continued)

(16) Calculate the total tube side pressure drop,

Pt

Pt = FtNsNp (Ptf + Ptr) + PN

For: Ft , see Table 1.01.
If the pressure drop is reasonably close to the value desired, proceed to the next
step. If it seems too high or low, change number of tube passes and repeat step
9 through 16 until the pressure drop is satisfactory.
(17) From Figure 2.02, determine the heat transfer correlation factor, Y th.
a. Calculate the thermal function:

cz

0.33

k
For hydrocarbons, refer to Figures 4.01 and 4.02.
b. Calculate the tubeside heat transfer coefficient, h io.

io

th

io

cz
k

0.33

z
z

0.14
w

0.14

Initially assume

Z
zw

= 1 , until tube wall temperature is calculated.

3.65

SHORTCUT PROCEDURE (Continued)

c. Estimate the average tube wall temperature, t w

tw = tt+Uo(Rio+rio) (ts-tt)
d. At the average tube wall temperature, determine z w and calculate:
0.14
Z
zw

(18) Recalculate hio using this viscosity correction.

(19) Calculate the tube wall resistance, r w

rw =

12kw

(See Tables 1.02-1.03)

7. Iteration, Shell Side
(1) Estimate tf, the average shell side film temperature.

tf =

( ts + tt ) + (Uo)
2

(Rio + rio + rw + ro) (Ts- tt)

3.66

SHORTCUT PROCEDURE (Continued)

(2)

At the average shell side film temperature, determine the following shell fluid properties:
a. For hydrocarbon liquids or vapors: Viscosity, z f.
b. For other fluids: Viscosity, z f; specific heat, cf; and thermal conductivity, kf.

(3)

Determine the number of tubes across the centerline of the tube bundle, NTC.
For square tube layout:

NTC = 1.19 (NT)0.5

For triangular layout:

NTC = 1.10 (NT)0.5

Determine the outer tube limit, D t.

(4)

Dt = (NTC - 1)(Pt) + do
(5)
Determine shell I.D. as follows:
D = Dt / 0.9; except for the following limitations:
1. Minimum D = D t + 1
2. Maximum D = D t + 3
(6)

Determine the free width for fluid flow normal to and around the tubes.

One shell pass, W = D - (do NTC) ; Two shell pass, W = D - (do NTC)
2

3.67

SHORTCUT PROCEDURE (Continued)

(7) Estimate the baffle pitch P b which will give a reasonable shell-side velocity
(3-15 fps). See Table 1.01 for maximum P b.
(8) Calculate the number of shell side baffles, N B (always a whole number).
NB = 10L/Pb
(9) Determine the free area, S, for fluid flow across the tube bundle between each pair
of baffles.
For Calculating the
Film Coefficient, h
Segmental Baffles:

For Calculating the

Pressure drop, P
S= W (Pb - 0.375)

Modified Disc &

Donut Baffles: S= W (Pb - 0.375)

S= W (Pb - 0.375

S= 0.85 W (Pb - 0.375)

In each case, 0.375 in. represents the approximate baffle thickness.

(10) Calculate the shell side mass velocity, G.
Disc and donut baffles, G = M/50S; Segmental baffles, G = M/25S

3.68

SHORTCUT PROCEDURE (Continued)

(11) Calculate the shell side linear velocity, V and the shell side nozzle velocity, V N
V = G/m
Vn =

(dN= Nozzle ID)

19.6md2N
(12) Calculate the shell side Reynolds number, N Re

NRe = doG/ Zf
(13) Calculate the ratio of the tube diameter to the tube spacing:

do
Pt - d o
From Figure 3.01 determine the shell side pressure drop correlation factor, Y SP.
Total Shell Side Pressure Drop
(14) Calculate the shell side velocity head and the nozzle velocity head.
2
mVN
9270

in the nozzles

2
mV

in the shell.

9270

3.69

SHORTCUT PROCEDURE (Continued)

(15) Calculate Psf, the frictional pressure drop per shell. Table 1.01 gives values for B2.

Psf

B2YspNTCNB

mV 2
9270

(Note!: For Disc & Donut baffles, divide NTC by 2.0)

(16) Calculate the pressure drop per shell due to turns, Psr, and the nozzle pressure drop, PN.

Psr = (NB + 1) 3.5 - 2Pb

D

mV 2

; PN =

9270

mVN 2
9270

(17) Calculate the total shell side pressure drop, Ps.

Ps

FsNs(Psr +Psf) + PN

For Fs, see Table 1.01.

If the pressure drop is reasonably close to the desired value, proceed to the next step. If it
seems too high or low, change the baffle pitch Pb and repeat steps 7 through 17 until the
pressure drop is satisfactory.

3.70

SHORTCUT PROCEDURE (Continued)

Shell Side Heat Transfer Coefficient, ho
(18)

From Figure 3.02 determine the heat transfer correlation factor, Ysh.

A. Calculate the thermal function:

kf

cfzf

1/3

kf
(For hydrocarbon liquids or vapors, refer to Figures 4.01 and 4.02)
b. Calculate the correction factor for the deviation from ideal baffle pitch.

4Pb

0.1

D
1

= ho = B1 Ysh kf cfzf

Ro

do

kf

4Pb

1/3

0.1

See Table 1.01 for B1

8. Duty Coefficient
Calculate Uo, the over-all duty heat transfer coefficient.

1 = Rt = Rio + rio + Ro + rw + ro
Uo
If Uo calculated does not agree with Uo assumed, repeat the calculations with a new U o
assumed until agreement is reached (10%).

3.71

SHORTCUT PROCEDURE (Continued)

9. Clean Coefficient
Calculate Uc, the over-all clean coefficient.

1 = Rc = Rio + rw + Ro + 0.001
Uc
10. Design Temperatures
Determine the following mechanical design features:
1. The design temperature and pressure of the shell and tube sides.
2. The nozzle size and flange rating for the inlets and outlets on both the shell
and tube sides.
3. The design temperature of the tube sheet, T M.
a.
For coolers (water on tube side), specify the higher result
of the following equations:

TM = TDT +
RC

Rio (TDS - TDT)

or

TM = TDT + (Rio + rio) (TDS - TDT)

Rt
b.
For other exchangers:
(1) When the fluid being cooled is on the tube side

TM = TDT - 0.1(TDT - TDS)

(2) When the fluid cooled is on the shell side

TM = TDT + 0.3 (TDS - TDT)

3.72

CALCULATION F0RM
SHORTCUT CALCULATION PROCEDURE
SHELL AND TUBE HEAT EXCHANGERS (NO CHANGE OF PHASE)
NOT FOR DEFINITIVE DESIGNS
Process_________________________________________
Exchanger No. E-_________________________________

Date____________________

1. Terminal Conditions and te

Fluid Being

Shell

T1 =__________,

Cooled: Tube
_________________
Fluid Being
Shell

tm = (T1-t2) - (T2-t1)
ln(T1-t2)

T1-T2 =__________,

t1 =__________,

t2-t1 =__________,

t2 =__________,

Heated: Tube
_________________

T2 =__________,

= T1-T2 _________

t2-t1
j = t2-t1 _________

T1-t1
T1 - t2 =__________, T2 - t1 =__________,
_________________

=__________

=__________

T1 - t1 =__________.

Fn =__________

for __________ shells

for __________shells

(T2-t1)

=__________ for __________shells

te = Fntm
=_________=_________ .
=_________=_________ .
2. Caloric Temperatures
tt, ts = 0.4 (t2 - t1) + t1 = (0.4)(

) + _________=_________F.

ts, tt = 0.4 (T1 - T2) + T2 = (0.4)() + _________=_________F.

3. Caloric Properties of Fluids4. Flow Rates, Stream Names, Nozzle I.D.
For Hydrocarbon Liquids or Vapors, and Water:
Tubes Shell
Tubes
Shell
Fluid = _________
_________
m=_________ lb./ft3
_________ lb./ft3
M = _________
z =_________ cP
dN = _________ in I.D. _________ In I.D.

Lb./Hr. _________

Lb./Hr.

3.73

CALCULATION FORM
(Continued)
For any other fluids, Also Obtain

5.

Tube

Fouling Factors:
(See top of next page for do and di.)

C=_________ Btu/lb. F

ri =_________________________.

K=_________ Btu/Hr. Ft. F

ro =_________________________.
2

rio = ri do

=___________ . ( __________ )2=

di

rio =_________________________.
6. Iteration, Tube Side
(1) Design Heat Duty, Q =______________ M Btu/hr.
(2) Assumed Value of Uo

First Trial

Second Trial

Third Trial

=_____________

_____________

_____________

=_____________

_____________

_____________

=_____________

_____________

_____________

L =_________ ft.

L =_________ ft.

L =_________ ft.

do=_________ in.;

di=_________ in.;

(3) A =

Q10
Uo Ate

(4) As = A/ Ns
(5) Tube Metal =__________ ;kw

=___________ .

=_________ in.

(6) Tube Pitch (Pt) and layout

=_____________

_____________

_____________

(7) NT = 3.82 As / (L-0.5)do

=_____________

_____________

_____________

(8) Assumed number of tube passes, Np

=_____________

_____________

_____________

3.74

CALCULATION FORM
(Continued)
First Trial

Second Trial

(9) V = NpM
19.6mdN

M
2

=_____________

_____________

19.6mNTdi

_____________

0.26

(10) If Tube Fluid

1.73

; VN =

Third Trial

hi

= 368 (Vdi)0.7

tt

=_____________

_____________

_____________

do

is Water

100

Pt = 0.020 FtNsNp V2 + 0.158LV

=_____________

_____________

_____________

di 1.27

(11) For Fluids Other than Water:

a. G = (V)(m) =_____________
_____________
_____________
(Remember to check for a
b. NRe = di G / Z Flow Transition Problem) =_____________
_____________
_____________
(12) From Fig. 2.01 Determine Ytp

=_____________

_____________

_____________

(13) mV / 9270;

=_____________

_____________

_____________

mVN / 9270

2
2

0.14 or 0.25

zw (See note below)

(14) Ptf = Ytp L mV
=_____________
_____________
_____________
9270
z (15) Ptr = 3(mV2/ 9270)
=_____________
_____________
_____________

(16) PN = 2(mVN/ 9270) for two nozzles

=_____________

_____________

_____________

(17) Pt = FtNsNp (Ptf + Ptr) + PN.

Ft = ____________. =_____________

_____________

_____________

Note to Item 14:

Use 0.25 for streamline flow

Until tw is calculated, use z w/z = 1.0

3.75

CALCULATION FORM
(Continued)
First Trial Second Trial

Third Trial

(18) From Fig. 2.02 Determine Yth

=_____________

_____________

_____________

a.

=_____________

_____________

_____________

=_____________

_____________

_____________

(CZ / K)1/3K (Figures 4.01-4.02)

1/3

hi* = Yth K CZ

b.
do

= 1/Ri* *Uncorrected
for Viscosity

c.

Tw = tt + Uo (Rio +rio) (ts-tt)

=_____________

_____________

d.

( z / zw )0.14 =_____________

_____________

_____________

(19) hio = hi* ( z / zw )0.14 * ( di / do )2 =_____________

_____________

(20) rw = l

_____________

=_____________

_____________

_____________

_____________

12 kw

7. Iteration, Shell Side

(1) tf =
2

(ts + tt)

First Trial

Second Trial

+ (Uo) (Rio +rio + rw + ro) (ts - tt)

Third Trial
=_____________

_____________

_____________

Zf =_____________

_____________

_____________

(2) For fluids other than hydrocarbons,

Determine film properties, for hydrocarbons

Cf =_____________
=_____________ _____________
_____________
(3) NTC + (1.19 or 1.10) (N T)0.5
1.10 For triangular
(4) Dt = (NTC - !) (Pt) + do

1.19 For square layout

=_____________

(5) D = Dt / 0.9 (Min. = Dt + 1; Max. = Dt + 3)

_____________

=_____________

_____________

_____________

_____________

_____________

=_____________

_____________

Determine only Zf.

Kf

_____________

_____________

(Maximum Permissible D typically = 48)

3.76

CALCULATION FORM
(Continued)
First Trial

Second Trial Third Trial

(6) W = D - (do NTC)

=_____________

_____________

_____________

(7) Assumed baffle pitch, =_____________

(For liquid service, minimum Pb = D.)

_____________

_____________

(8) NB = 10L / Pb =_____________

_____________

For D & D Baffles,

(9) S = W ( Pb - 0.375) use 0.85 S for =_____________
P (only).
(10)G = M / 25S (Segmental) ; M/50S (D& D)
M

(11)V = G / m ; VN =

_____________
_____________

=_____________

=_____________

_____________

_____________

_____________

_____________

_____________

19.6mdN

(12)NRe = doG / zf =_____________

(13)

do

Pt-do

_____________

_____________

= ______ . From Fig 3.01 Determine YSP =_____________

_____________

_____________

(14)mV2 / 9270; mVN / 9270 =_____________

(15)Psf = YspNTCNB
9270

_____________

(B2=_________ .)

mV

_____________

B2

(See note below)

=_____________

_____________

mV

_____________

_____________

_____________

(16)Psr = (NB + 1) 3.5 - 2Pb

D

=_____________

9270

(17)PN = 2(mV2 / 9270) for two nozzles

(18)Ps = FsNs (Psr + Psf) + PN

=_____________

=_____________

_____________

_____________

_____________

_____________

Fs = _______ .
Note to item 15: For disc & donut baffles, use NTC / 2 for pressure drop.

3.77

CALCULATION FORM
(Continued)
First Trial
Second Trial
Third Trial
(19)From Fig. 3.02 Determine Ysh
=_____________ _____________
a. Kf(CfZf / Kf) 1/3 =_____________

_____________

_____________

b. (4Pb / D) 0.1

_____________

_____________

=_____________

_____________

=_____________
1/3

(20)ho =
do

B1Ysh

cf z f

Kf

kf

_____________

0.1

4Pb

_____________

B1=_________ .
8. Duty Coefficient

First Trial

Second Trial

Third Trial

Rio=_____________

_____________

_____________

Ro =_____________

_____________

_____________

rio =_____________

_____________

_____________

Uo

_____________ (1st. Trial)

ro =_____________

_____________

_____________

_____________ (2nd. Trial) rw =_____________

_____________

_____________

_____________ (Final)

_____________

_____________

1 = Rt =_____________

Uo

3.78

CALCULATION FORM
(Continued)
9. Clean Coefficient
Rio

_____________

Ro

_____________

rw

_____________

Scale = 0.0010
1

Rc

Rio + rw + Ro + 0.0010

= _____________ ; Uc = _____________ .

Uc

10. Design Temperature

a. Tube side design temperature = _____________ F = T DT
b. Shell side design temperature = _____________ F = T DS
c. Tube sheet design temperature = TM
(1) For Coolers
TM = TDT + Rio (TDS - TDT)=
Rc

or
TM = TDT + (Rio + rio) (TDS - TDT)=
Rt

Calculate TM from both equations, and specify the higher value: TM= ___________F
(2) For Exchangers
Tube side fluid is being cooled:
TM = TDT - 0.1(TDT - TDS)=
Shell side fluid is being cooled:
TM = TDT - 0.3(TDS - TDT)=

3.79

TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
SHELL SIDE
Maximum Allowable Baffle Pitch Maximum Pb, Inches
Tube O.D. Inches
Steel Copper, Aluminum Alloys
0.75 30.0 26.0
1.00 37.0 32.0
1.50 50.0 43.5
(For no change of phase, Pb should not exceed the shell ID.
Heat Transfer & Pressure Drop Factor B 1 and B2
Baffle Position

Tube Layout

Transfer B1

Pressure Drop B2

Vertical to tube rows

Square
0.50 0.30
On the bias (45)
Square
0.55 0.40
Vertical to tube rows
Triangular
0.70 0.50
Pressure Drop Fouling Factors, F s
Fluid Fs
Liquids
1.15
Gases or condensing vapors

1.00

TUBE SIDE
Pressure Drop Fouling Factors Typical Tube Pitch
Tube O.D. Inches
Ft
Tube O.D. Inches
Pitch In
0.75 Steel 1.50 0.75 Triangular
1.00 Steel 1.40 0.75 Square
1.50 Steel 1.20 1.0 Square
0.75 Copper Based
1.20 1.5
1.00 Copper Based
1.15

0.9375
1.0
1.25
Square

1.875

3.80

TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
(Continued)
TUBE SIDE (Continued)
Design Cooling Water Velocity
Most Favorable
Velocity, ft/sec

Permissible
Range, ft/sec (4)

Material

Type of Water

Carbon Steel

Fresh, non-inhibited
Fresh, inhibited

4
6 to 8

3 to 6
3 to 10

Red brass

All types

6 to 8

3 to 4

Admiralty (inhibited)

Fresh (inhibited or not)

Salt or brackish

6 to 8
3

3 to 10
3 to 5

Aluminum brass

Fresh (inhibited or not)

Salt or brackish

6 to 8
5

3 to 10
4 to 8

Cupronickel (70-30)

All types

7 to 8

6 to 12

Cupronickel (90-10)

All types

7 to 8

6 to 12

Monel

All types

6 to 12

Type 316 alloy steel

All types

10

8 to 15

3.81

TABLE 1.02
EXCHANGER TUBE DATA
l = Wall

do=
O.D. of
Tubing, In.
3/4
3/4
3/4
3/4
1
1
1
1
1 1/2
1 1/2
1 1/2

BWG
12
14
16
18
10
12
14
16
10
12
14

GAGE EQUIVALENTS
Inches
BWG
0.220
5
0.165
8
0.148
9
0.134
10
0.120
11
0.109
12
0.095
13
0.083
14
0.072
15
0.065
16
0.058
17
0.049
18
0.035
20

Thickness
In. (3)
0.109
0.083 (1)
0.065 (2)
0.049
0.134
0.109 (1)
0.083 (2)
0.065
0.134
0.109
0.083

di =
I.D. of
Tubing, In.
0.532
0.584
0.620
0.652
0.732
0.782
0.0834
0.870
1.232
1.282
1.334

Internal Cross

External Surface

Sectional Area
Sq. In.
0.223
0.268
0.302
0.334
0.421
0.479
0.546
0.594
1.192
1.291
1.397

Per Foot Length

Sq. Feet
0.1963
0.1963
0.1963
0.1963
0.2618
0.2618
0.2618
0.2618
0.3927
0.3927
0.3927

MAXIMUM RECOMMENDED NUMBER OF TUBE PASSES

Shell ID Inches
Max. Passes
<10
4
10-19
6
20-29
8
30-39
10
40-49
12
51-59 (Rare)
14
Notes:
(1) Typical wall thickness for carbon steel tubes.
(2) Typical wall thickness for copper alloy tubes.
(3) Average wall thickness is typically 10% greater than the minimum wall thickness.
Tubes may be specified (and purchased) on either an average wall or minimum wall
basis. (Exxon normally specifies minimum wall.)

3.82

TABLE 1.03
THERMAL CONDUCTIVITIES OF METALS AT TYPICAL HEAT EXCHANGER TEMPERATURES
Material
Composition
Thermal Conductivity, k,
Admiralty (71 Cu - 28 Zn - 1 Sn) 64
Type 316 Stainless Steel
(17 Cr - 12 Ni - 2 Mo) 9
Type 304 Stainless Steel
(18 Cr - 8 Ni)
9
Brass
(70 Cu - 30 Zn)
57
Red Brass
(85 Cu 15 Zn)
92
Aluminum Brass
(76 Cu - 22 Zn - 2 Al) 58
Cupro-Nickel
(90 Cu - 10 Ni)
41
Cupro-Nickel
(70 Cu - 30 Ni)
17
Monel
(67 Ni - 30 Cu - 1.4 Fe)
15
Inconel
11
Aluminum 117
Carbon Steel
26
Carbon-Moly Steel (0.5 Mo) 25
Copper
223
Lead
20
Nickel
36
Titanium 11
Chrome-Moly Steel (1 Cr - 0.5 Mo)
24
(2-1/4 Cr - 0.5 Mo)
22
(5 Cr - 0.5 Mo)
20
(12 Cr - 1 Mo)
16

3.83

TABLE 1.04
TYPICAL FOULING FACTORS
Stream Type
Vapor Overheads
Virgin Distillate liquids to tankage
Virgin Distillate liquids from tankage
Cracked distillate liquids from tankage
Reduced Crudes
Tar, bitumen
Cracked Tar
Crudes
Steam
BFW
Cooling Water, Fresh
Cooling Water, Salt

Typical ri or ro
0.001
0.001
0.002
0.002
0.004
0.005
0.010
0.0102-0.004
0.001
0.001
0.0015 - 0.0025
0.0025 -0.0035

3.84

TABLE 1.05
SOME TYPICAL OVERALL COEFFICIENTS
Type of Source

Typical Uo

Light Ends Liquid Coolers (Water)

Distillate Coolers (Water)
Light Ends Reboilers (Steam)
Light Ends Feed/Bottoms

120
70-90
80
100

Crudes/distillates
Condensers (Tower overheads)

25-50
90

3.85

NOMENCLATURE
A

Total exchanger are, ft 2 Ro

As
B1
B2

Area/shell, ft.

Total resistance (duty) to heat transfer (Note 1).

Bundle factor for shell side heat transfer

Bundle factor for shell side pressure drop , dimensionless

ro

Specific heat at caloric temperature, Btu/Lb -F.

Resistance of tube wall metal at average wall temperature(Note 1).

Cf

Specific heat of the shell side fluid at average film temperature, Btu/lb - F S

Shell I.D., inches TDS

Dt

Diameter of tube bundle (outer tube limit), inches

di

Tube I.D., inches TM

Tube sheet design temperature, F.

do

Tube O.D., inches T1

Inlet temperature of fluid being cooled, F.

Fn

Correction factor for log mean temperature difference (due to partially

Rt

Concurrent flow), dimensionless

Outside film resistance to heat transfer, (Note 1).

rio

rw

Inside fouling factor corrected to outside area, (Note 1).

-

Outside fouling factor (Note 1).

-

Free flow area between shell baffles, in.

Design temperature of the shell side, F.

t1

T DT

Design temperature of the tube side, F.

T2

Outlet temperature of fluid being cooled, F.

Inlet temperature of fluid being heated, F.

Fs

Shell side pressure drop correction factor, dimensionless

t2

Outlet temperature of fluid being heated, F.

Ft

Tube side pressure drop correction factor, dimensionless

tf

Average shell side film temperature, F.

Mass velocity, lbs/sec - ft2

hio

Inside film coefficient corrected to outside area, Btu/hr-ft 2-F.

ho

Outside film coefficient Btu/hr-ft 2 -F tw

Thermal conductivity at caloric temperature, Btu/hr-ft 2-F/Ft.

kf

Thermal conductivity of the tube metal at average tube temperature, Uo

kw

Btu/hr-ft -F/ft
Thermal conductivity of the tube metal at average tube temperature, V

Tube wall thickness, in. VN

L
M

Tube length, ft.

W
Mass rate, lbs/hr. Ysh

Free width between baffles, in.

Shell side heat transfer correlation factor.

Density, lbs/ft3

Shell side pressure drop correlation factor.

NB

Number of shell baffles Yth

NP

Number of tube passes per shell.

NRe

Reynolds number, inch-lbs/sec-ft 2 - centipoise

NS

Number of shells in series.

NT

Number of tubes across in the bundle

NTC

Number of tubes across the center line of the bundle

Pb

Baffle pitch, inches.

Ptr

Tube pressure drop due to turns, psi/tube pass.

Pt

Tube pitch, inches.

Pt

Total tube side pressure drop, psi.

Rate of heat transfer, Btu/hr.

Psf

RC

Total resistance (clean) to heat transfer (Note 1) Psr

Rio

Inside film resistance corrected to outside area, (Note 1)

ts

Caloric temperature of the shell fluid, F.

-

tt

Caloric temperature of the tube fluid, F.

Average tube wall temperature, F.

Uc

Over-all clean coefficient of heat transfer, Btu/hr-ft 2-F.

-

Over-all duty coefficient of heat transfer, Btu/hr-ft 2-F.

Velocity in the tubes or shell ft/sec.

Ysp

zf

Velocity in the nozzles, ft/sec.

Tube side heat transfer correlation factor.

Ytp
-

Tube side pressure drop correlation factor.

z

Viscosity at caloric temperature, centipoises.

Viscosity of the shell side fluid at average film temperature, centipoises.

zw

Viscosity of the tube side fluid at tube wall temperature, centipoises,

Ptf

Tube pressure drop due to friction, psi/tube pass.

Shell side pressure drop due to friction, psi/shell.

-

Shell side pressure drop due to friction, psi/shell.

PN

Nozzle Pressure drop, psi/shell.

Ps -

Total shell side pressure drop, psi.

te

Long mean temperature difference corrected for non-ideal countercurrent flow

(Effective temperature difference) F.

tew Weighted effective log mean difference, F.

3.86

FIGURE 1.01
LMTD CORRECTION FACTORS

3.87

FIGURE 1.02
LMTD CORRECTION FACTORS

3.88

FIGURE 1.03
LMTD CORRECTION FACTORS

3.89

FIGURE 2.01
FRICTIONAL PRESSURE DROP FOR
FLUIDS FLOWING IN TUBES

3.90

FIGURE 2.02
HEAT TRANSFER COEFFICIENT FOR LIQUIDS IN TUBES

3.91

FIGURE 3.01
FRICITONAL PRESSURE DROP
FLUIDS FLOWING ACROSS TUBE BANKS

3.92

FIGURE 3.02
HEAT TRANSFER COEFFICIENT
FLUIDS FLOWING ACROSS TUBE BANKS

3.93

FIGURE 4.01
VALUES OF THE THERMAL FUNCTION
k(PRANDTL NO.)1/3 FOR LIQUID HYDROCARBONS

3.94

FIGURE 4.02
VALUES OF THE THERMAL FUNCTION
K(PRANDTL NO.)1/3 FOR HYDROCARBON VAPORS

3.95

ADDENDUM 4.02
FOR FLOW INSIDE TUBES APPROXIMATE EFFECT OF VARIABLES IN THE
TRANSFER OF MOMENTUM AND HEAT
To Find P2
To Find h2
Property Changed Multiply P1 By:
NRe > 10,0000 (Note 1)
Linear Velocity

Multiply h1 By:

Turbulent Flow

(V2/V1)1.8 (V2/V1)0.8

Tube Diameter (at constant linear velocity)

(D1/D2)1.2 (D1/D2)0.2

Viscosity( 2/ 1)0.2 ( 2/ 1)0.5

Density (at constant linear velocity) ( 2/ 1)0.8 ( 2/ 1)0.8
NRe > 2,100 (Note 1)

Laminar Flow*

Linear Velocity

(V2/V1)0.33

V2/V1

Tube Diameter (at constant linear velocity)

Tube Diameter (at constant weight rate)
Density (at constant linear velocity

(D1/D2)2

(D1/D2)4

(D1/D2)0.33

D1/D2

No dependence

( 2/ 1)0.33

Tube Length L2/L1 (L1/L2)0.33

Note 1: This is dimensionless Reynolds Number.

3.96

Section
Date

I X-B

Page

HEAT EXCHANGE EQUIPMENT

DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

3.97

Section
Date

I X-B

Page

HEAT EXCHANGE EQUIPMENT

DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

3.98

Section
Date

I X-B

Page

HEAT EXCHANGE EQUIPMENT

DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

3.99

Section
Date

I X-B

Page

HEAT EXCHANGE EQUIPMENT

DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

3.100

Section
Date

I X-B

Page

HEAT EXCHANGE EQUIPMENT

DESIGN CONSIDERATIONS FOR ALL
TYPES OF HEAT EXCHANGERS

EXXON DESIGN PRACTICES

PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

3.101

Attachment IX - Safety Factor Selection

3.102