Effective thermal design of shell and tube heat exchangers is essential for maintaining performance and reducing costs in industries such as oil, gas, petrochemicals, and energy. In a field where heat exchangers are a significant investment, understanding how to design them efficiently is vital.
Optimization for Thermal Design of Shell and Tube Heat Exchangers presents a clear, practical approach to achieving optimal results with minimal trials. Incorporating real-world examples and fast-track methodologies, this authoritative guide provides valuable tools to improve efficiency and manage data effectively while running design programs. Mehdi Hanifzadeh, a seasoned process principal engineer with more than 38 years of experience, offers proven strategies to reduce construction and maintenance costs while maintaining high design standards.
Providing step-by-step guidance to designing these essential components with accuracy and speed, this book: - Designed in oil refineries, gas processing, petrochemicals and power plants. - Helps readers reduce construction costs while complying with industry design standards - Focuses on practical design methods and data management for cost-effective, high-quality outcomes. - Provides clear and transparent design and calculation methods illustrated through numerous real-world examples and case studies - Serves as a valuable educational and training resource for readers
This title is an invaluable resource for new designers and experienced professionals specializing in the design and optimization of heat exchangers, and an ideal textbook for advanced chemical and mechanical engineering students taking courses in process design, energy systems, and industrial equipment.
Table of Contents
PrefaceAbout this book
Audience / Reader
Global Thermal Design Software
Chapter 1 A Brief Overview
1.1 Short Summary of Each Chapter
1.2 Shell-and-Tube Heat Exchangers
1.3 Step by Step Thermal Design Methodology
1.4 Why Shell-and-Tube
1.5 Scope of shell-and-tube
1.6 Shell & Tube Heat Exchanger Components / Definition
1.7 Fouling
1.8 Thermodynamic Analysis of a Heat Exchangers
Chapter 2 Required Data for Starting Thermal Design
2.1 Process Data Sheets
2.2 Contract & Project Specifications
Chapter 3 Practical Input Data for Thermal Design (using Software)
3.1 Calculation Modes
3.2 Process Data for Hot / Cold Side
3.3 Physical Property Data for Hot / Cold Side
3.4 Fouling Resistant
3.5 TEMA Type
3.6 TEMA Class
3.7 Shell Inside Diameter
3.8 Exchanger Orientation
3.9 Hot & Cold Fluid Location
3.10 Examples for TEMA Type Selection
3.11 Heat Load & EMTD
3.12 No. of Shell in Series & Parallel
3.13 Tube Type
3.14 Tube Outside Diameter
3.15 Tube Pattern
3.16 Tube Length
3.17 Tube Pass
3.18 Material of Construction
3.19 Tube Sheet
3.20 Baffle Type
3.21 Baffle Cut Percent
3.22 Baffle Spacing
3.23 Flow Fraction in Shell
3.24 Clearances & Shell-Side Leakages
3.25 Nozzle Data
3.26 Impingement Plate
3.27 Reboilers
3.28 Vibration of Tubes
3.29 Emerging New Technology
3.30 Basic Principles path of Thermal Design in Computer program
Chapter 4 Features of an Optimal Design for a Heat Exchanger
4.1 Result Output Data (of any Computer Program
4.2 Over Design Percent
4.3 Calculated Pressure Drop
4.4 Flow Velocity / Rho.V2 Analysis
4.5 Shell-Side Flow Distribution
4.6 Baffle Spacing Center to Center
4.7 Effective Temperature Difference
4.8 Shell and Tube Heat Transfer Coefficients
4.9 Two Phase Flow Regimes
4.10 Vibration Analysis
4.11 Kettle Type Output Data
Chapter 5 Optimization Logic
5.1 The Factors that influence the Capital / Operating Cost of an Exchanger
5.2 Step by Step Optimization Method
5.2.1 How to Control General Item
5.2.2 How to control Shell-side Pressure Drop
5.2.3 How to control Tube-side Pressure Drop
5.2.4 How to control Shell-side Velocity / Heat Transfer Parameters
5.2.5 How to control Tube-side Velocity / Heat Transfer Parameters
5.2.6 How to control and remove Vibration Problem
Chapter 6 Practical Thermal Design for Real Example Cases
6.1 Water Cooler-1
6.2 Water Cooler-2
6.3 Gas Water Cooler-3
6.4 Lube Oil Water Cooler-4
6.5 No phase Change-1
6.6 No Phase Change-2
6.7 Boiler Feed Water Heater-No Phase Change-3
6.8 Feed & Effluent Heat Exchanger-1
6.9 Feed & Effluent Heat Exchanger-2
6.10 Condenser-1
6.11 Condenser-2
6.12 Condenser-3
6.13 Reactor Effluent Condenser-4
6.14 Kettle Type-1-C3 Refrigerator
6.15 Kettle Type-2-Steam Boiler
6.16 Kettle Type Reboiler
6.17 Horizontal Thermosiphon Reboiler-1
6.18 Horizontal Thermosiphon Reboiler-2
6.19 Vertical Thermosiphon Reboiler-1
6.20 Vertical Thermosiphon Reboiler-2
Chapter 7 Brief Description of Activities after Thermal Design
7.1 Mechanical Design
7.1.1 General Guidelines for Mechanical Design
7.1.2 Thickness Design for all Pressure Parts
7.1.3 Finalization of Tube-sheet Layout
7.1.4 Tube-sheet
7.1.5 Nozzle
7.1.6 Flanges
7.1.7 Saddle Support / Lifting Lug
7.2 Fabrication
7.2.1 Various Steps for Fabrication
7.2.2 Using Automatic Machine
7.2.3 Manufacturing Tolerances
7.2.4 Fabrication Precaution for Special Items
7.2.5 Final Transportation / Shipment
7.3 Inspection and Testing
7.3.1 Inspection
7.3.2 Testing
7.4 Installation
7.4.1 Installation Stages
7.5 Operation of a Heat Exchanger
7.5.1 Pre-Commissioning of a new Heat Exchanger
7.5.2 Common Instrumentation and Control System
7.5.3 Removing Condensate from Exchanger, when Steam is used
7.5.4 When does an Exchanger need to be Shut-down?
7.6 Maintenance and Repairment
7.6.1 Periodic Maintenance of heat exchangers
7.6.2 General steps consideration during design stage
7.6.3 List of Special Tools for Maintenance
7.6.4 List the steps in the maintenance of a heat exchanger
7.6.5 Maintenance Record
7.6.6 Areas of an Exchanger require in-service inspection
7.6.7 Using Modern Software for Preventive Maintenance
7.6.8 Leaking Determination in an Operating Heat Exchanger
7.6.9 The Specific detection Method for Leaky tubes and joints
7.6.10 Plug and Replace method for Leaky Tubes
7.6.11 Precaution for Unbolting Flange Connection
7.6.12 Precaution for Removing a Tube-bundle
7.6.13 General Cleaning Methods
7.6.14 Various ways of Cleaning the Inside / Outside of the tube
7.6.15 Back Flushing
Chapter 8 Comparison between ASME Code and TEMA Standard
8.1 ASME Code
8.2 TEMA Standard
8.2.1 TEMA List of Content
8.3 Main Difference between TEMA and ASME
8.4 Conclusion
Chapter 9 Brief Description of TEMA Standard
9.1 Nomenclature
9.2 Fabrication Tolerances
9.3 General Fabrication and Performance Information
9.4 Installation, Operation, and Maintenance
9.5 Mechanical Standards TEMA class RCB Heat Exchangers
9.6 Flow Induced Vibration
9.7 Thermal Relations
9.8 Physical Properties of Fluids
9.9 General Information
9.10 Recommended Good Practice
References
Index
