400 Shell and Tube Exchanger
Design and Selection
Abstract
This section contains information on TEMA nomenclature, selecting the most
economic exchanger configuration for a defined service, allocating the streams to
shell or tube side, specifying appropriate mechanical components, defining baffle
layout, deciding if a small predesigned exchanger is appropriate, and estimating the
size and cost of shell and tube exchangers.
Contents
Chevron Corporation
Page
410
TEMA (Tubular Exchanger Manufacturers Assoc.) Nomenclature 400-2
420
General Design Considerations
430
Stream Placement
400-11
440
Pass Arrangements and Multiple Shells
400-12
450
Bundle and Tubesheet Arrangements
400-13
451
Front Head Design
452
Fixed Tubesheets
453
U-tubes Versus Floating Rear Heads
454
TEMA F Shell
460
Shell Side Baffle and End Spaces
400-14
470
Small Exchangers
400-15
480
Estimating Methods
400-16
481
Step by Step Procedure
482
Surface Area Calculations
483
Tube Count and Number of Tube Passes
484
Shell Diameter
485
Exchanger Investment Cost
400-1
400-2
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400 Shell and Tube Exchanger Design and Selection
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410 TEMA (Tubular Exchanger Manufacturers Assoc.) Nomenclature
The Tubular Exchanger Manufacturers Association (TEMA) has developed nomenclature for describing shell and tube heat exchangers. It includes a simple code for
designating the size and type of the exchanger. In addition, standard terminology
has been set up to specify typical parts and connections.
TEMA size is the shell inside diameter in inches rounded to the nearest integer,
followed by the straight length of the tubes in inches rounded to the nearest integer.
The two dimensions are separated by a hyphen (-).
For kettle reboilers, the port diameter in inches precedes the shell inside diameter.
The two dimensions are separated by a slash (/). Port diameter is the size of the
opening the bundle slides through.
TEMA type consists of three letters describing the stationary or front end head,
shell, and rear head, in that order. The letter designations are shown on
Figure 400-1.
For example, a 20-foot straight length U-tube bundle, 3-foot shell diameter, with a
single shell pass and removable shell cover would be a TEMA SIZE 36-240 TYPE
AEU. The same bundle installed in a 5-foot diameter kettle reboiler would be a
TEMA SIZE 36/60-240 TYPE AKU.
Standard terminology to describe components and connections of shell and tube
exchangers is provided in Figure 400-2.
TEMA sets mechanical standards for three classes of exchangers reflecting the
severity of the service. For most refinery services, the most restrictive class is
usedTEMA Class R. For other services (chemical plants for example), TEMA
Class C or B exchangers are used. In general, Class R exchangers have thicker
shells, larger and thicker heads, thicker tubes, and larger miscellaneous parts.
TEMA requirements are noted where appropriate throughout this manual.
420 General Design Considerations
Single- and two-phase exchangers and most condensers have very similar configurations. The typical layout is summarized in the following list and shown in Figures
400-3 and 400-4. (Steam generators (2 types), reboilers, and condensers are
described in Sections 340, 350, 360 and 370.)
The typical shell and tube exchanger geometry includes the following items:
December 1989
TEMA E shell style
U-tubes for rear head type with full support plate at tangent
TEMA A-type front head
Single segmental baffles with cut of 18 to 25% of shell I.D. and with cut
oriented vertically
Baffle spacing of 20 to 100% of shell I.D
400-2
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Fig. 400-1
400 Shell and Tube Exchanger Design and Selection
Heat Exchanger Nomenclature (TEMA, Figure N-1.2) (Courtesy of TEMA)
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400 Shell and Tube Exchanger Design and Selection
Fig. 400-2
Heat Exchanger and Cooling Tower Manual
Heat Exchanger Components (1 of 3) (TEMA, Table N-2 and Figure N-2) (Courtesy of TEMA)
1. Stationary HeadChannel
21. Floating Head CoverExternal
2. Stationary HeadBonnet
22. Floating Tubesheet Skirt
3. Stationary Head FlangeChannel or Bonnet
23. Packing Box
4. Channel Cover
24. Packing
5. Stationary Head Nozzle
25. Packing Gland
6. Stationary Tubesheet
26. Lantern Ring
7. Tubes
27. Tierods and Spacers
8. Shell
28. Transverse Baffles or Support Plates
9. Shell Cover
29. Impingement Plate
10. Shell FlangeStationary Head End
30. Longitudinal Baffle
11. Shell FlangeRead Head End
31. Pass Partition
12. Shell Nozzle
32. Vent Connection
13. Shell Cover Flange
33. Drain Connection
14. Expansion Joint
34. Instrument Connection
15. Floating Tubesheet
35. Support Saddle
16. Floating Head Cover
36. Lifting Lug
17. Floating Head Flange
37. Support Bracket
18. Floating Head Backing Device
38. Weir
19. Split Shear Ring
39. Liquid Level Connection
20. Slip-on Backing Flange
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Fig. 400-2
400 Shell and Tube Exchanger Design and Selection
Heat Exchanger Components (2 of 3) (TEMA, Table N-2 and Figure N-2) (Courtesy of TEMA)
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400 Shell and Tube Exchanger Design and Selection
Fig. 400-2
Heat Exchanger and Cooling Tower Manual
Heat Exchanger Components (3 of 3) (TEMA, Table N-2 and Figure N-2) (Courtesy of TEMA)
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Typical Longitudinal Section Shell and Tube Exchanger
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Fig. 400-3
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400 Shell and Tube Exchanger Design and Selection
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Fig. 400-4
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Typical Cross Section, Shell and Tube Exchanger
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400 Shell and Tube Exchanger Design and Selection
3/4-inch O.D., 14 BWG (average) thickness (0.584 inch I.D.) carbon steel tubes
Tube length variable with one or two tube passes depending on service
45 degree rotated square layout with tube pitch = 1.25 tube O.D. for liquid
and two-phase hydroprocessing shell side service
90 degree square layout with tube pitch = 1.25 tube O.D. for boiling,
condensing, and single-phase gas shell side service
Two or more pairs of sealing strips (bars)
Dummy tubes in pass partition lane when two tube passes
Two rows of impingement rods at inlet nozzle when warranted
Overall Exchanger Configuration
The Company preference is a TEMA AEU exchanger for most services. U-tubes
are the cheapest rear head type that allows for thermal expansion of the tubes. The
TEMA A type front head has a removable channel cover. This allows for inspection
and cleaning of the tube side without pulling spool pieces in the piping.
Shell Side Nozzle Placement
Single inlet and outlet shell side nozzles are normally located at opposite ends of
the exchanger with one on the top and one on the bottom of the shell. This arrangement allows vents and drains to be located in piping.
Route two-phase flow based on the following rule: Heat up and cool down. This
means hot fluid being condensed should enter on the top and exit on the bottom of
the exchanger. Likewise, cold fluid being boiled should enter on the bottom and
exit on the top. The Heat up and cool down rule does not apply to single-phase
flow.
Transverse and Support Baffles
The normal configuration for the tube side consists of U-tubes with a full support
plate at the tangent. This is shown in Figure 400-3. The plate blocks flow over the
U-bends. Otherwise, the bends must be supported to protect against vibration.
For baffles, use single segmental baffles with a cut of around 18 to 25% of the shell
I.D. for most efficient conversion of pressure drop to heat transfer. The baffle cut
should be vertical for best drainage of the shell side at shutdown. Baffle thickness is
set by TEMA.
Baffle spacing should be 20 to 50% of the shell I.D. It is usually set to maintain
good heat transfer (economic pressure gradient or shear controlled flow regime).
Guidelines for economic exchanger velocity and pressure drop are provided in
Section 220 of this manual. In some cases (particularly for gas and two-phase flow
shell side), additional supports may be required to prevent vibration. See
Section 260 of this manual for more information.
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Tube Selection
Tubes are normally 3/4-inch outside diameter, 14 BWG (minimum) thickness (0.56inch inside diameter), and made of carbon steel. Length is limited by the plot space
for pulling the bundle and standard bundle pulling equipment. TEMA has named 8,
10, 12, 16 and 20 feet as standard tube lengths. Other lengths are possible.
Alloy tubes are appropriate for some services. The cost of upgrading to alloy tubes
should always be weighed against possible process adjustments to permit carbon
steel construction. Section 800 of this manual discusses materials selection for
different services.
Tubepass Layout
Most exchangers should be limited to one or two tube passes. Using U-tubes with
two passes is best and cheapest, however some services dictate 1 pass with a more
expensive rear head (vertical thermosiphon reboilers or crude/overhead condensers,
for example).
Tube Pitch
For liquid and two-phase services, use 1-inch, 45 degree rotated square pitch. This
promotes mixing. Use 1-inch, 90 degree square pitch for boiling, condensing, and
single-phase gas on the shell side. For boiling, the vertically oriented lanes promote
circulation. For condensing and single-phase gas, in-line tubes minimize pressure
drop without sacrificing heat transfer. Both 45 and 90 degree pitch provide 0.25inch inspection and cleaning lanes through the bundle.
Preventing Shell Side Flow Bypassing
Single- and two-phase exchangers with impingement protection typically include
two pairs of sealing strips (bars). The bars block the leakage stream flowing around
the baffles between the bundle and shell (C stream shown in Figure 200-3 in
Section 213). For vertical cut baffles, the bars straddle the nozzles (located at the
top and bottom of the bundle). Note that the bars on the bottom act as skid bars for
bundle removal.
For an exchanger with two tube passes, the single pass partition lane runs perpendicular to the baffle cuts. Dummy tubes are positioned in the pass partition lane to
block flow bypassing (F stream shown in Figure 200-3 in Section 213). Dummy
tubes are spaced four to six tube rows apart between baffle cuts and are the same
diameter as the tubes.
Impingement Protection
When impingement protection is warranted, the preferred method is to install two
rows of rods (typically tubes over solid rods) adjacent to the inlet nozzle.
Section 524 contains design details and applications of impingement rods along
with descriptions of other types of impingement protection.
Tolerances and Clearances
All tolerances and clearances are TEMA.
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400 Shell and Tube Exchanger Design and Selection
430 Stream Placement
Allocating the streams to the shell or tube side is determined by weighing factors
which sometimes conflict. These factors include stream temperature, pressure, relative flowrate, viscosity, corrosiveness, relative heat transfer film coefficient, and
pressure drop limitations. Guidelines for allocating the streams to the shell or tube
side are given in Figure 400-5.
Fig. 400-5
Allocating the Streams for Shell and Tube Heat Exchangers
In Order of Decreasing Priority:
Stream Property
Compared to Other Stream
Preferred Side
Shell
Tube
Match Coefficients and Pumping
Power
Lower Film Coefficient Expected
(hshell / htube <0.3)
Condensing
Determined by coolant
Corrosion inhibitors effective tubeside; otherwise use alloy tubes
Staggered tube layout induces
good heat transfer at low Reynolds
number
Alloy Required for Corrosion
Very Low System Pressure or P
Available
X
X
Normal Fouling
Allows cheaper shellside components
Can use J or X shell style to
shorten flow path and reduce pressure drop
High System Pressure
High T across one Bundle (Over
200F)
Minimize cost
Enhance outside surface to raise
limiting side coefficient (singlephase gas only)
Treated Cooling Tower Water
Viscosity above 2 cP
Reasons for This Choice
Reduces shell thickness;
however, tube rupture design
sometimes controls
Excessive T in stationary
tubesheet if placed on
tubeside
Does not matter
Deposits Too Hard to
Hydroblast (Rare)
Use floating rear head for straight
tubes
Complete Tube Plugging (Rare)
Use floating rear head for straight
tubes
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440 Pass Arrangements and Multiple Shells
The appropriate stream pass arrangements for a particular service are based on:
Providing economic pressure gradient on both sides of exchanger
Operating in shear controlled flow regime for two-phase flow
Limiting pressure drop
Controlling temperature efficiency
On the tube side, the pressure gradient is adjusted by changing the number of tubes
per pass. To get more area, increase the flow path length either by using longer
tubes, by adding more shells in series, or by increasing the number of tube passes.
Note that two tube passes are typical because more passes dramatically increase
pressure drop. Not only does the pressure drop increase proportionally to the
increase in flow path length, but to the square of velocity. For example, going from
two to four passes increases the pressure drop by a factor of eight with the tube
count held constant.
On the shell side, the pressure gradient is adjusted by changing the baffle spacing.
To get more area, the exchanger (tube length) is made longer. When more area is
needed and the tube length is maximum, add another shell with the shell side flow
in series.
The shell style is changed from a TEMA E-type to a TEMA J- or X- type when the
resulting pressure drop is too large at the target pressure gradient. This shortens the
flow path allowing the pressure gradient to be maintained.
Use parallel exchangers only when a single exchanger is too large, and the pressure
drops can not be increased at the target pressure gradients. Exchanger size is
limited by the manufacturers fabricating equipment and the users maintenance
equipment. Space availability may also limit size, especially when modifying an
existing unit.
Parallel units with isolation valves have been used to provide an installed spare or
when flow rates will vary more than 50% from normal. When the flow rate varies,
the number of units onstream is changed to maintain reasonable operating pressure
drop.
Consider using a mixed parallel/series arrangement of shell and tube passes in
multiple units only when required to meet pressure drop restrictions. The overall
temperature efficiency of the units is reduced. Note that the F-factor described in
Section 211 of this manual is the common measure of temperature efficiency.
Temperature efficiency will vary with service. Area is most effectively used when
shell and tube side stream routing approaches pure countercurrent flow (F-factor of
1.0). Going to multiple units in series increases the temperature efficiency. Keep the
F-factor above approximately 0.85.
When performance is limited by a temperature pinch between the streams (small
local temperature difference reflected as low F-factor), multiple shells become cost
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400 Shell and Tube Exchanger Design and Selection
effective by reducing the total area requirement. Countercurrent flow of both fluids
through the shells maximizes efficiency.
For condensing services, significant subcooling loads are usually processed in a
separate exchanger following the condenser. This allows the geometry to be
changed to accommodate the much lower volumetric rate of the liquid. As a result,
the area needed for subcooling is reduced.
450 Bundle and Tubesheet Arrangements
This section covers front head selection, fixed tubesheet applications, U-tubes
versus floating rear heads, and TEMA F shells (two shell pass exchangers).
451 Front Head Design
The TEMA Type A front stationary head is normally used. It has a removal channel
cover so the tube side can be inspected without disconnecting nozzles or removing
pipe spools. The bonnet channel (Type B) is cheaper and is appropriate for small
exchangers with small easily removed pipe spools. For operating pressures above
1000 psig, a special front head is required. Options are discussed in Section 532.
452 Fixed Tubesheets
Fixed tubesheets are the cheapest type of head. They are typically used when the
shell side service is nonfouling and noncorrosive, and the metal temperature of the
shell and tubes operate within 50F (including startup, shutdown and steam out
conditions). The bundle is not removable.
The shell side is not accessible for inspection or mechanical cleaning since the
tubesheets are seal welded to the shell. If the temperature difference is larger than
50F, an expansion joint may be required in the shell.
Steam generators with very high (1000F and above) process side temperatures and
water on the shell side must have fixed tubesheets. See Section 350 of this manual
for more information.
453 U-tubes Versus Floating Rear Heads
U-tube and floating head bundles are removable. Both permit thermal expansion of
the tubes. The various types of rear heads are shown on Figure 400-1.
U-tubes (TEMA Type U) are the cheapest of the two types and are preferred. The
bends can be mechanically cleaned by hydroblasting for typical fouling deposits
as long as complete plugging does not occur.
One disadvantage of U-tube bundles is that corrosion is difficult to monitor. Specimen tubes can only be taken from the outside perimeter of the bundle.
TEMA Type S and T floating rear heads cost more than U-tubes. Maintenance is
complicated by the added bundle flange. Floating heads can be taken apart and the
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straight tubes drilled out. Floating heads are recommended for services leaving
deposits too hard to hydroblast.
The differences between the S- and T-type heads are minor. The split ring (S) type
allows for tight clearance between the shell and bundle. However, a shell body
flange and the split ring flange must be taken apart before the bundle can be pulled.
The pull through (T) type allows the bundle to be removed prior to taking apart the
floating head and does not require a shell body flange. However, the shell is oversized to allow the floating head to pass through.
Floating heads (versus fixed tubesheets) are usually necessary for single tube pass
exchangers to accommodate thermal expansion. Head design must account for
startup, shutdown, and steam out conditions. Single pass exchangers with a floating
head are commonly used for atmospheric column overhead condensers in crude
units and vertical thermosiphon reboilers.
454 TEMA F Shell
The TEMA F shell has a longitudinal baffle running through the middle of the
exchanger. This provides two shell passes within one shell. Both the inlet and outlet
shell side nozzles are located adjacent to the tubesheet (channel end).
When coupled with two tube passes, the F shell provides pure countercurrent flow.
F shells have been used instead of multiple shells in series to avoid temperature
pinches. F shells are cheaper than multiple shells in series. However, experience has
shown the seal between the two shell passes to be very difficult to maintain.
Increased maintenance time and performance loss due to leakage by the longitudinal baffle is reported frequently.
As a result, TEMA F shells are currently recommended for noncorroding and
nonfouling services onlywhere the tube bundle is rarely if ever pulled for maintenance.
If the bundle from a F shell is pulled, the seal (described in Section 523) is usually
replaced. The bundle must be handled carefully when reinstalled. The seal is easily
ruined if the slings twist the seal or the bundle goes in crooked.
460 Shell Side Baffle and End Spaces
The number of crosspasses, the baffle spacing (central, inlet and outlet spacing),
and the straight tube length are related mathematically. For a TEMA E shell with Utubes fully supported at the bend tangent, the following relationship applies.
F = C (cp - 2) + D + E + tbst
(Eq. 400-1)
where:
F = Straight (total) tube length in inches
C = Central baffle spacing in inches
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400 Shell and Tube Exchanger Design and Selection
cp = Number of crosspasses per shellpass
D = Inlet baffle spacing in inches
E = Outlet baffle spacing in inches
tbst = Tubesheet thickness in inches
End (inlet and outlet) spaces are set to keep the transverse baffles clear of the inlet
and outlet nozzles. The spacing accounts for mechanical constraints which force the
nozzle position. These include flange thickness, body and nozzle flange clearances,
nozzle reinforcement and access. For a TEMA E shell with U-tubes, end spaces can
be estimated using the following equations.
End space at channel or tubesheet in inches:
1.1 (nozzle I.D., inches) + 0.1 (shell I.D., inches) + 8.0
End space at rear end or free end of bundle in inches:
1.1 (nozzle I.D., inches) + 2.0
The actual spacing can be wider, but should not be excessive. Heat transfer in the
end spaces is not as good as between transverse baffles.
470 Small Exchangers
There are two types of small exchangers: the double pipe and the multitube hairpin.
Both are predesigned in set configurations, and provided by vendors off the shelf.
They are designed to be stacked nozzle to nozzle as shown in Figure 400-6.
Fig. 400-6
Typical Stack of Small Exchangers
Figure 400-7 is diagram of a double pipe exchanger. It is simply a single pipe
within a pipe. Fluid flow on the shell side simplifies to flow through an annulus.
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Figure 400-8 is a diagram of a multitube hairpin exchanger. It is a shell and tube
exchanger with one U-shell and one U-tube pass. Figure 400-9 gives typical
exchanger geometries.
Fig. 400-7
Double Pipe Exchanger
Fig. 400-8
Multitube Hairpin Exchanger
The same economic considerations for setting pressure gradient or velocity apply to
small exchangers as to conventional shell and tube exchangers. Small exchangers
are cost effective when the required surface area is less than about 250 ft2 for
double pipes and less than 1000 ft2 for multitube hairpins.
Because the configuration is already fixed, you should confirm exchanger geometry
with the vendor. The HTRI programs can be used to model double pipe and multitube hairpin exchangers. See the Heat Exchanger Design Program Users Guide for
details.
480 Estimating Methods
This section gives procedures for estimating the size and cost of a shell and tube
exchanger. The procedures are recommended for:
December 1989
Preliminary sizing and layout of a new exchanger prior to rigorous computer
modeling
Developing project economics
Comparing performance or configuration of an existing exchanger to a defined
standard or baseline exchanger
400-16
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Multitube Hairpin Exchanger Information (1 of 2)
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400 Shell and Tube Exchanger Design and Selection
Multitube Hairpin Exchanger Information (2 of 2)
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Fig. 400-9
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400 Shell and Tube Exchanger Design and Selection
481 Step by Step Procedure
Step 1.
Estimate physical and thermal properties for streams. Calculate
exchanger duty (MMBtu/hr). Allocate streams to shell and tube sides
using the guidelines in Section 430.
Step 2.
Plot heat release curve for stream(s) undergoing phase change. Estimating techniques must be carefully applied to streams with dramatic
slope changes. More information and an example are provided in
Section 211.
Step 3.
Estimate the actual mean temperature difference (MTD). This depends
on the service of the exchanger. See Section 211.
Step 4.
Determine if multiple shells in series are required. See Section 440.
Step 5.
Select appropriate film coefficients from Figure 400-10. Appropriate
sections of this manual that contain more accurate methods are referenced in Figure 400-10.
Step 6.
Calculate a overall service heat transfer coefficient U. See Section 212.
Step 7.
Calculate the required surface area for the service. See Section 482.
Step 8.
Determine the number of tubes per shell and pass configuration. See
Section 483.
Step 9.
Estimate the shell diameter for given tube count. See Section 484.
Step 10.
Estimate shell and tube side pressure drop, if needed. See Section 220.
Step 11.
Cost the exchanger, if needed. See Section 485.
482 Surface Area Calculations
Area (A) for heat transfer is calculated from the overall heat transfer expression for
the service.
Q
A = ---------------------U MTD
(Eq. 400-2)
where:
A = Surface area for heat transfer, ft2
Q = Heat duty for service, Btu/hr
MTD = Mean temperature difference for service, F
U = Overall service heat transfer coefficient, Btu/hrFft2
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483 Tube Count and Number of Tube Passes
The number and length of the tubes is determined through trial and error. The two
are related by the necessary mechanical configuration of the exchanger to provide
the surface area (A) calculated in Section 482.
Fig. 400-10 Approximate Heat Transfer Film Coefficients for a Well Designed Heat Exchanger(1) (2)
Service or Fluid
Shell or Tube Side Coefficient,
Btu/hrFft2 [based on bare
outside area]
Reference
SENSIBLE
1400
450
400
250
150
Pure Water
C.T. Water(3)
HC, 0.5 cP
HC, 2 cP
HC, 10 cP
Figure 200-4
Section 213
GASES
Light HC, 150 psig
Air, 10 psig
Air, 300 psig
100
15
60
Appendix B
CONDENSING
1000
200
100
50
Steam
Light HC
Heavy HC
Subcooling(4)
Section 370
BOILING
Water
Light HC
Heavy HC
1000
300
150
Section 360
175
Section 600
AIR COOLED (FIN FAN)
Air Side(5)
(1) This table applies to well designed exchangers (fouling is controlled and flow regime is shear controlled or turbulent to promote heat
transfer).
(2) The film coefficients are on a clean basis. Allowance for extra area is applied separately.
(3) Cooling tower water film coefficient includes thermal resistance of corrosion inhibitor film.
(4) Subcooling coefficient applies for condensate cooling in the condenser. Typically subcooling is accomplished in a separate condensate cooler.
(5) Tubes are finned.
A = (#tubes) (L) () (O.D.) / 12
(Eq. 400-3)
where:
#tubes = Number of tubes per pass, dimensionless
= Mt / [(t) (Vt) (3600) (At)]
At = Cross sectional area of single tube, ft2
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400 Shell and Tube Exchanger Design and Selection
= () (I.D./12)2/4
L = Flow path length, ft (in heat transfer)
= 3.142
O.D. = Tube outside diameter, inches
I.D. = Tube inside diameter, inches
Mt = Mass flow rate of tube side fluid, lb/hr
t = Fluid density of tube side fluid, lb/ft3
Vt = Velocity of tube side fluid, ft/sec
For single-phase, two-phase, and some condensing services, use the economic
sizing guidelines (Section 220) to select velocity (Vt), or a range of reasonable
velocities. Use an initial flow path length of 40 feet. This assumes a 20-foot long Utube exchanger with two tube passes and a full support plate at the bend tangent.
Through trial and error calculations, determine a tube count that meets the area and
velocity requirements. The flow path length may change. Consider leaving the flow
path at 40 feet, and ending up with more excess area. Be careful when specifying
exchangers with other than two tube passes. Be careful of a long flow path. The
pressure drop can be excessive.
Note that multiple tube pass exchangers have an even number of tube passes to
accommodate thermal expansion.
If tube side fluid is pure component condensing or boiling, velocity can generally
be ignored. Set tube length and calculate tube count for area. For vertical thermosiphons (VTSR) with tube side boiling, 8- to 12-foot tubes are typical with only one
tube pass. The actual length depends on the service as well as velocity and exit pipe
flow regime. Further definition is beyond the scope of this section.
484 Shell Diameter
For a typical U-tube exchanger with two tube passes, 0.75-inch tubes on a 1-inch
rotated square (45 degree) pitch and impingement rods, the shell diameter in inches
is given by:
Shell I.D. = 1.95 [#tubes]0.433 (for shell I.D. between 15 and 51 inches)
(Eq. 400-4)
Shell diameter should be rounded to the nearest 1/16 inch. The correlation is based
on shell side nozzle diameters between 20 to 30% of the shell inside diameter.
Within the constraints, the correlation is good to plus or minus 2%. If nozzles are
relatively smaller, the tubes may fit into a smaller shell. And, if nozzles are larger, a
larger shell may be required to accommodate all the tubes.
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485 Exchanger Investment Cost
Exchanger investment cost is calculated using techniques from the Company Cost
Estimating Books. For shell and tube heat exchangers with design pressure below
600 psi for both sides, the installed cost is:
HEX = (EDMI/655) (I) (T) [ (MTL) (A) + CMP (F + m A) ]
(Eq. 400-5)
where:
HEX = Installed cost of exchanger, $
EDMI = Chevron material index, dimensionless
I = Installation factor for heat exchanger, dimensionless
T = Multiplier for geographic location adjustment, sales and other
taxes, dimensionless
MTL = Tube material adjustment, $/ft2 (at 655 EDMI)
A = Area for heat transfer, ft2 (Note that installed cost is directly
proportional to areaexponent of 1.0.)
CMP = Configuration and component adjustment including component
material multipliers, dimensionless (See Cost Estimating Book)
F = Fixed cost add on which is a function of exchanger class (small
or large) and design pressure, $ (at 655 EDMI)
m = Multiplier reflecting linear cost change with area, $/ft2; the multiplier is a function of exchanger classsmall or largeand
design pressure
For a typical exchanger configuration with all carbon steel construction and 300 psi
design pressure (both sides), the expression simplifies to:
HEX = (EDMI/655) 5.5 [13,100 + (8.8 A)]
(Eq. 400-6)
This equation assumes that the installation factor (I) is 5.5, area and tax adjustment
(T) is 1.065, material add on (MTL) is 0, and configuration adjustment (CMP) is
0.935. CMP is for 20 feet (straight length) U-tubes. F and m are for exchangers
with 1000 ft2 or more.
The cost expression is different for high pressure shell and tube heat exchangers
(design pressure well above 600 psi). Cost varies with the area to the 0.64 power.
See the Cost Estimating Books for details.
December 1989
400-22
Chevron Corporation
