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Shell&Tube Thermal Design of Shell & Tube Heat Exchangers Page 1 of 47
Shell&Tube Thermal Design of Shell & Tube

Heat Exchangers
Shell&Tube Input
Shell&Tube Results
Shell&Tube Getting Started Guide
Shell and Tube Heat Exchanger Geometry
Quick Guide to Geometry Selection
Shell&Tube Input
Problem Definition
Headings/Remarks
Application Options – Calculation Mode, Fluid allocation, Application Types, Equipment Types
Process Data – Temperatures, Pressures, Flows, Quality, Pressure Drops, Fouling, Heat Load
Physical Property Data
Stream Composition
Stream Properties – Property Databanks, Stream Definition, Property Tables
Exchanger Geometry
Geometry Summary – Geometry, Tube Layout
Shell/Heads/Flanges/Tubesheets – Shell/Heads, Covers, Tubesheets, Flanges
file://C:\Documents and Settings\Asim\Local Settings\Temp\~hhA90D.htm 6/3/2010

Tubes – Tube, Low Fins, Longitudinal Fins, Inserts, KHT Twisted Tubes
Baffles/Supports – Baffles, Tube Supports, Longitudinal Baffles, Variable Baffle Pitches
Bundle Layout – Layout Parameters, Layout Limits/Pass Lanes, Tie Rods/Spacers, Tube Layout
Nozzles – Shell Side Nozzles, Tube Side Nozzles, Domes/Belts, Impingement
Thermosiphon Piping – Thermosiphon Piping, Inlet Piping Elements, Outlet Piping Elements
Construction Specifications
Materials of Construction – Vessel Materials, Cladding/Gasket Materials, Tube Properties
Design Specifications
Program Options
Design Options – Geometry Options, Geometry Limits, Process Limits, Optimization Options
Thermal Analysis – Heat Transfer, Pressure Drop, Delta T, Fouling
Methods/Correlations – General, Condensation, Vaporization, Enhancement Data
Calculation Options – Calculation Options
Shell&Tube Problem Definition

The Problem Definition section includes the following screens:
Headings/Remarks
Application Options
Process Data
Shell&Tube Headings/Remarks
The Headings/Remarks section includes the following screens:
TEMA Specification Sheet Descriptions

Shell&Tube Application Options

The Application Options screen contains the following inputs:
General
Calculation Mode
Location of Hot Fluid
Select Geometry based on this Dimensional Standard
Calculation Method
Hot Side
Application
Condenser Type
Simulation Calculation
Cold Side
Application
Vaporizer Type
Simulation Calculation
Thermosiphon Circuit Calculation
Shell&Tube Process Data

The Process Data screen contains the following inputs:

Fluid Name
Mass Flow Rate
Temperature
Vapor Mass Fraction
Operating Pressure
Pressure at Liquid Surface in Column
Heat Exchanged
Adjust if Over-Specified
Estimated Pressure Drop
Allowable Pressure Drop
Fouling Resistance
Physical Property Data Overview

For each stream within the exchanger there are two input sections:
Composition
Properties
Within the Composition section, the Physical Property Package (Properties Data Source) can be
selected.
The following property package options are available:
Aspen Properties
COMThermo
B-JAC Databank
User Specified Properties

Two other options are shown to indicate when the properties data have been generated by a process
simulator. These are not facilities for generating properties with the stand-alone program:
Aspen Plus
HYSYS
The selection of the property package will dictate what subsequent inputs are requested and what
screens may be displayed. The property package input will indicate where physical properties have
come from or where they will be coming from.
The basic physical properties will consist of one to five data sets of stream properties at various
temperature points which should encompass the operating temperatures of the exchanger. Each data set
would represent a different operating pressure. It is recommended that multiple data sets at different
pressure be used for applications involving changes of phase or gas only since the pressure change
through an exchanger can significantly impact the properties and heat release curves for these
applications. Data at two pressures are adequate for most exchangers, with more only needed when the
pressure change in the exchanger is a significant fraction of the inlet pressure.
The Properties section includes the following screens:
Properties
Phase Composition
Component Properties
Properties Plots
See also:
Refrigerant Cross Referencing Table
Shell&Tube Exchanger Geometry

The Exchanger Geometry section includes the following screens:
Geometry Summary

Shell/Heads/Flanges/Tubesheets
Tubes
Baffles/Supports
Bundle Layout
Nozzles
Thermosiphon Piping
Shell&Tube Geometry Summary

The Geometry Summary section includes the following screens:
Geometry
Tube Layout
Shell&Tube Shell/Heads/Flanges/Tubesheets
The Shell/Heads/Flanges/Tubesheets section includes the following screens:
Shell/Heads
Covers
Tubesheets
Flanges
Shell&Tube Tubes
The Tubes section includes the following screens:
Tube

Low Fins
Longitudinal Fins
Inserts
KHT Twisted Tubes
Shell&Tube Baffles/Supports
The Baffles/Supports section includes the following screens:
Baffles
Tube Supports
Longitudinal Baffles
Variable Baffle Pitches
Shell&Tube Bundle Layout

The Bundle Layout section includes the following screens:
Layout Parameters
Layout Limits/Pass Lanes
Tie Rods/Spacers
Tube Layout
Shell&Tube Nozzles
The Nozzles section includes the following screens:

Shell Side Nozzles
Tube Side Nozzles
Domes/Belts
Impingement
Shell&Tube Thermosiphon Piping

The Thermosiphon Piping section includes the following screens:
Thermosiphon Piping
Inlet Piping Elements
Outlet Piping Elements
Shell&Tube Construction Specifications

The Construction Specifications section includes the following screens:
Materials of Construction
Shell&Tube Materials of Construction

The Construction Specifications section includes the following screens:
Vessel Materials
Cladding/Gasket Materials
Tube Properties
Shell&Tube Design Specifications

The Design Specifications section includes the following screens:
Shell&Tube Program Options

The Program Options section includes the following screens:
Design Options
Thermal Analysis
Methods/Correlations
Calculation Options
Shell&Tube Design Options

The Design Options section includes the following screens:
Geometry Options
Geometry Limits
Process Limits
Optimization Options
Shell&Tube Thermal Analysis
The Thermal Analysis section includes the following screens:
Heat Transfer
Pressure Drop
Delta T
Fouling
Shell&Tube Methods/Correlations
The Methods/Correlations section includes the following screens:
General
Condensation
Vaporization

Enhancement Data
Shell&Tube Calculation Options

The items on this sheet let you specify whether to use the Standard or Advanced calculation method, and
to select various options available with the Advanced method:
Calculation Method
Convergence Options
Maximum Number of Iterations
Convergence Tolerance - Heat Load
Convergence Tolerance - Pressure
Relaxation Parameter
Calculation Grid Resolution
Convergence Criterion
Calculation Step Size
Pressure Drop Options
Pressure drop calculations options - cold side
Pressure drop calculations options - hot side
Shell&Tube Results
Input Summary
Result Summary

Warnings & Messages
Optimization Path
Recap of Designs
TEMA Sheet
Shell&Tube Summary
Thermal / Hydraulic Summary
Performance – Overall Performance, Resistance Diagram
Heat Transfer – Heat Transfer Coefficients, MTD & Flux, Duty Distribution
Pressure Drop – Pressure Drop, Thermosiphon Piping, Thermosiphon Piping Elements
Flow Analysis – Flow Analysis, Thermosiphons and Kettles
Vibration & Resonance Analysis – Fluid-Elastic Instability, Resonance Analysis, TEMA Fluid Elastic
Instability, TEMA Amplitude and Acoustic Analysis
Methods
Mechanical Summary
Exchanger Geometry
Setting Plan
Tubesheet Layout
Cost / Weights
Calculation Details
Analysis along Shell
Analysis along Tubes
Analysis for X and K shell

Shell&Tube Input Summary
This section provides you with a summary of the information specified in the input file.
It is recommended that you request the input data as part of your printed output so that it is easy to
reconstruct the input, which led to the design.
Shell&Tube Result Summary
The Result Summary section includes the following screens:
Warnings & Messages
Optimization Path
Recap of Designs
TEMA Sheet
Shell&Tube Summary
Shell&Tube Warnings & Messages
Aspen Shell & Tube Exchanger provides an extensive system of errors, warnings and other messages to
help you use the program. They are for the most part self explanatory, and contain information on the
values of parameters which have led to the reported condition. There are several hundred messages built
into the program, and these can be divided into number of types.
Range Checking Warning.
These relate to input values which are outside the range of what is normally expected. You should check
that the input value referred to is correct. If so the message can usually be ignored, though for unusual
exchanger geometries, or unusual fluid properties, it is likely that the uncertainty in the results is
exacerbated.
Input Omission Error
These identify input parameters which are necessary for the program to run. Whether a particular
parameter is necessary can depend on the values of other parameters. Required input is normally
identified in the User interface, though there are occasionally instances where a required item is not
highlighted in the Interface, or where an item is shown as required by the interface, does not lead to an

error when the program is run.
Range Checking Error
These identify input values which are beyond the range of what is permitted. They cause program
execution to cease.
Results Warning
The run has completed, but problems have been identified with some part of the calculation, which
indicate that some aspect of the results may be subject to more uncertainty than normal.
Results Error
The run has either failed to generate a significant part of the results, or failed to complete in some way
that many of the results given should not be relied on.
Operation Warning
The run has completed, but is predicting operation which does not meet normal practice, or is in some
other way inadvisable, or in extreme cases impracticable.
Advisory
There is some feature of the exchanger, or its operation which is unusual, and for which better
alternatives may exist.
Notes
Any other information which may be useful.
Shell&Tube Optimization Path
This part of the output is the window into the logic of the program. It shows some of the heat exchangers
the program has evaluated in trying to find one, which satisfies your design conditions. These
intermediate designs can also point out the constraints that are controlling the design and point out what
parameters you could change to further optimize the design.
To help you see which constraints are controlling the design, the conditions that do not satisfy your
specifications are noted with an asterisk (*) next to the value. The asterisk will appear next to the
required tube length if the exchanger is undersurfaced, or next to a pressure drop if it exceeds the
maximum allowable.
In design mode, Shell&Tube will search for a heat exchanger configuration that will satisfy the desired
process conditions. It will automatically change a number of the geometric parameters as it searches.

However Plate will not automatically evaluate all possible configurations, and therefore it may not
necessarily find the true optimum by itself. It is up to the user to determine what possible changes to the
construction could lead to a better design and then present these changes to the program.
Shell&Tube searches to find a design that satisfies the following:
(1) enough surface area to do the desired heat transfer
(2) pressure drops within the allowable
(3) physical size within acceptable limits
(4) velocities within an acceptable range
(5) mechanically sound and practical to construct
In addition to these criteria, Shell&Tube also determines a budget cost estimate for each design and in
most cases performs a vibration analysis. However cost and vibration do not affect the program's logic
for optimization.
There are over thirty mechanical parameters which directly or indirectly affect the thermal performance
of a shell and tube heat exchanger. It is not practical for the program to evaluate all combinations of
these parameters. In addition, the acceptable variations are often dependent upon process and cost
considerations which are beyond the scope of the program (for example the cost and importance of
cleaning). Therefore the program automatically varies only a number of parameters which are
reasonably independent of other process, operating, maintenance, or fabrication considerations.
The parameters which are automatically optimized are:
shell diameter baffle spacing pass layout type
tube length number of baffles exchangers in parallel
number of tubes tube passes exchangers in series
The design engineer should optimize the other parameters, based on good engineering judgment. Some
of the important parameters to consider are:
shell type tube outside diameter impingement protection
rear head type tube pitch tube pattern
nozzle sizes tube type exchanger orientation
tubesheet type baffle type materials
baffle cut fluid allocation tube wall thickness

Shell&Tube Recap of Designs
The recap of design cases summarizes the basic geometry and performance of all designs reviewed up to
that point. The side by side comparison allows you to determine the effects of various design changes
and to select the best exchanger for the application. As a default, the recap provides you with the same
summary information that is shown in the Optimization Path. You can customize what information is
shown in the Recap by selecting the Customize button. You can recall an earlier design case by selecting
the design case you want from the Recap list and then select the Select Case button. The program will
then regenerate the design results for the selected case.
Shell&Tube TEMA Sheet
The TEMA sheet displays the results from the thermal calculations using the standard datasheet detailed
in TEMA standard and includes a basic Setting Plan.
Shell&Tube Summary
Shell&Tube Thermal / Hydraulic Summary

The Thermal / Hydraulic Summary section includes the following screens:
Performance
Heat Transfer
Pressure Drop
Flow Analysis
Vibration & Resonance Analysis
Methods
Shell&Tube Performance

The Performance section includes the following screens:
Overall Performance
Resistance Distribution
Shell&Tube Heat Transfer

The Heat Transfer section includes the following screens:
Heat Transfer Coefficients
MTD & Flux
Duty Distribution
Shell&Tube Pressure Drop

The Pressure Drop section includes the following screens:
Pressure Drop
Thermosiphon Piping
Thermosiphon Piping Elements
Shell&Tube Flow Analysis

The Flow Analysis section includes the following screens:
Flow Analysis
Thermosiphons and Kettles
Shell&Tube Vibration & Resonance Analysis

The Vibration & Resonance Analysis section includes the following screens:
Fluid-Elastic Instability
Resonance Analysis

TEMA Fluid Elastic Instability
TEMA Amplitude and Acoustic Analysis
Shell&Tube Methods
The Methods Summary screen lists all the models and methods that have been used by the program as
part of the calculations.
Shell&Tube Mechanical Summary

The Mechanical Summary section includes the following screens:
Exchanger Geometry
Setting Plan
Tubesheet Layout
Cost / Weights
Shell&Tube Exchanger Geometry

The geometry used in the calculations is summarized in a series of screens:
Basic Geometry
Tubes
Baffles
Supports-Misc. Baffles
Bundle
Enhancements
Thermosiphon Piping

Shell&Tube Setting Plan

The Setting Plan details a scaled drawing of the exchanger and includes the following data:
Overall length
Bundle/Tube Pulling Length
Location and orientation of Nozzles
Location and orientation of Supports
Location of Baffles
The following tables are also included:
Headings/Remarks
Design Codes and Standards
Design Data
Weight Summary
Nozzle Data
Click the left-hand mouse button to zoom in on an area of interest.
Click the right-hand mouse button to display a menu from which the following options can be selected:
Exchanger only
End Views only
Draw Internals
Draw Border
Inlet Channel on Left
Nozzle/Shell Intersection

Dimension to Tubesheet Face
Draw Complete Exchanger
Draw Dimensions
Nozzle Designations
The Setting Plan can be:
Printed
Copied to the clipboard
Saved as in file in the following formats: dxf, bmp, svg, wmf
Shell&Tube Tubesheet Layout

The Tubesheet Layout details a scaled drawing of the Tube Layout as used as part of the thermal
calculations. No editing of the drawing is permitted as this is an output view. To make changes to the
Tube Layout refer to the ‘Exchanger Geometry – Geometry Summary – Tube Layout’ screen.
The tube layout diagram includes the following data:
Shell Side Inlet and Outlet Nozzles
Shell Cylinder (Shell Kettle Cylinder - if K Shell)
Tube Locations
Pass Partition Lanes
Baffles
Tie Rods
Impingement Plate
Sealing Strips
Bundle Runners
Longitudinal Baffle

Pass Partition Lane Sealing Strips
The following tables can be selected to view the data associated which each item:
Bundle Limits
Pass Regions
Nozzles
Baffles
Tie Rods
Tube Lines
Impingement Plate
Sealing Strips
Bundle Runners
Longitudinal Baffle
Pass Partition Lane Sealing Strips
Click the left-hand mouse button to zoom in on an area of interest.
Click the right-hand mouse button to display a menu from which the following options can be selected:
Draw tubes as circles
Draw tubes as crosses
Draw end tubes as circles
Draw border
Draw dimensions
Display titles

The Tubesheet Layout can be:
Printed
Copied to the clipboard
Saved as in file in the following formats: dxf, bmp, svg, wmf
Shell&Tube Cost / Weights

This screen summarizes the weights calculated for the major components in the exchanger, and includes
an empty weight and a weight flooded with water.
The total cost for the exchanger is also listed with a break down of the cost into total labor and material.
Shell&Tube Calculation Details

The Calculation Details section includes the following screens:
Analysis along Shell
Analysis along Tubes
Analysis for X and K shell
Shell&Tube Analysis along Shell

The Analysis along Shell section includes the following screens:
Interval Analysis
Physical Properties
Shell&Tube Analysis along Tubes

The Analysis along Tubes section includes the following screens:
Interval Analysis
Physical Properties
Shell&Tube Analysis for X and K Shell

The Analysis for X and K shell section includes the following screens:
Interval Analysis
Overview
The purpose of this example is to guide you through the design a simple single-phase heat exchanger
using Aspen Shell & Tube Exchanger (Shell&Tube).
Contents:
Process Overview
Building the Simulation
Viewing the results
Properties from COMThermo
Creating a Checking Case
The Design calculation will determine the shell length and diameter, the nozzle sizes, the number of
tubes and passes, the number of baffles and baffle cut. Other details such as shell and header type, baffle
type, tube type and layout will use program defaults.
The Shell&Tube design logic will optimise the heat transfer against the allowable pressure drop on both
the shell and tube sides. The program has built in heuristic rules, which will stop it searching once it
realizes that further calculations are pointless.
Help may be obtained at any time by placing the cursor on an item and pressing F1
Next step:
Process Overview
Process Overview

The details of the process data and some basic geometry are shown in the table below:
Fluid Cold Side Hot Side Units
Boiler Feedwater Fuel Oil

Total Flowrate 59100 284000 kg/h
Temperature (In/Out) 50 / 165.3 213 / 168 °C
Density (In/Out) 879.4 / 909.8 kg/m³
Specific Heat (In/Out) 2.34 / 2.18 kJ/kg*K
Viscosity (In/Out) 1.94 / 3.37 mPa*s
Thermal Conductivity (In/Out) 0.1 / 0.107 W/m*K
Inlet Pressure 50 12 bar (abs)
Allowable Pressure Drop 1 1.5 bar
Fouling Resistance (min) 0.000088 0.0005 m2 °K/W
Note: Exchanger to be Horizontal
Next step:
Launch Aspen Exchanger Design & Rating (EDR) from either the shortcut or the AspenOneTool bar.
Select Shell & Tube Exchanger (Shell&Tube) from the New tab and click OK.

Shell&Tube will open where the screen as shown below will be displayed.

To change the units which data can be entered into the program there are a number of options;
Click on the drop down arrow by US and select SI units
From the menu bar, select Tools, then Program Settings. From the General tab set SI as the Default set
of the units of measure. Click OK, where the next time Shell&Tube is started, SI units will be the
default set of unit.

Highlight the Application Options from the tree menu structure on the left-hand side and then ether the
data as follows;
Set the calculation mode to Design
Location of hot fluid to Tube side

Press the Next button to navigate to the next form where input data is required or highlight Process Data
from the navigation tree. Enter the process data from the process overview table previously given.
The flowrate data has been specified as kg/h whereas the input screen by default shows kg/s. Therefore
click on the scroll down arrow by the mass flowrate units and select kg/h then enter the data.
When sufficient data has been entered necessary for the program to run, the red cross will disappear
from the menu tree.
(NOTE: Numbers in red are program defaults and are not entered by the user)

Enter the physical properties for the hot side fluid, where as property data is supplied at two temperature
points. User Specified Properties is selected for the property package.

Enter the property data for the two temperature points.
By default, two pressure levels are available, where in this example data at only one pressure level is to
be entered. To delete the second pressure level you have two options:
Enter 1 for the number of pressure levels
Highlight the second pressure level in the Pressures column then click on the Delete Set button.
(NOTE: The Overwrite properties box is checked for direct input of properties)

Use one of the physical property packages to retrieve the cold stream properties.

Either B-JAC Databank or COMThermo can be selected. Initially the B-JAC databank will be described
below, but in the Continuation Exercise 2 the COMThermo method is used.
Select B-JAC databank as the Physical property package and then click on the Search Databank button.
Type in the first few letters of the fluid required, then highlight from the list and click on the Add button
to enter in the selected components list. Click on OK.

Select the Cold Side Properties tab and click on the Get Properties button where the program will
calculate the properties of water at the default pressure and temperature range.

Save your case – All the required data have been entered. It is important to save the dataset. This is
achieved from the menu by File, then Save As. Now you can run by clicking on the Run button or from
the menu, Run, then Run TASC.
Next step:
Viewing the results
Viewing the Results

Now the example has been run the Results screens can now be viewed
Next step:
The above example used B-JAC database to determine the physical properties for the cold stream.
COMThermo can be used instead, where the method is described below.
Reload the Design case and re-run.
Select COMThermo as the Physical property package for the Cold side composition. Click on the
Search Databank button.
Type in the first few letters of the fluid required, then highlight from the list and click on the Add button
to enter in the selected components list. Click on OK.

Enter a composition fraction of 1 for water and then from the Property Methods tab select Ideal-Ideal as
the property package

Select the Cold Side Properties tab and click on the Get Properties button where the program will
calculate the properties of water at the default pressure and temperature range.

Run Shell&Tube and compare the areas with the Design generated with B-JAC Database.
Next step:

The Design mode of Shell&Tube will provide a number of designs that will achieve the required duty.
These can be viewed on the ‘Results | Results Summary | Optimization Path’ tab. Here there will be a
list of the different geometries evaluated by Shell&Tube indicating if they meet the duty and pressure
drop requirements and also if they are a "near" miss. At the top of this table is the ‘Current selected
case’ number that meets both the duty and pressure drops and has the lowest cost value.
In order to fine tune and fully optimize the design the Rating/Checking mode in Shell&Tube should be
used.
Select ‘Run’ from the main menu and then ‘Update file with Geometry – Shell&Tube’. This will take
the optimized heat exchanger geometry and create a Rating/Checking case.
The detailed geometry of the exchanger can now be changed if necessary from the Exchanger Geometry
screens.
Return to:
Overview
Shell and Tube Heat Exchanger Overview
A shell and tube exchanger has a bundle of tubes within a shell. One stream flows through the tubes, the
other in the shell, over the tubes. Many variants of this basic configuration exist. Further information on
the various components of an exchanger, and on the reasons for selecting particular sizes or
configurations, is available on the following key topics:
Shell and Head Types
TEMA Shell Types
Head Types
Shell/Head Combinations
Double Pipe and Multi-tube Exchangers
Shell Diameters
Pass Arrangements
Single Pass Exchangers

Allocation of Streams
Nozzles - Sizing
Nozzles - TEMA Standards
Nozzles - Achieving TEMA Standards
Tube Bundles
Tube Diameters
Tube Wall Thicknesses
Common Tube Diameters and Thicknesses
Standard Bare Tube Diameters and Gauges
Tube Pattern and Tube Pitch
Tube Length - Maximum Value
Tube Length / Number of Passes
Tube Counts
Baffle Types
Single Segmental Baffles
Double Segmental Baffles
Triple Segmental Baffles
Orifice Baffles
Disc and Doughnut Baffles

Rod Baffles
Baffle Cut Orientation
Baffle Spacing and Cut
Maximum Unsupported Tube Span Length
Sealing Strips
Expansion Joints
Quick Guide to Geometry Selection
TEMA
Shell&Tube Shell and Head Types
Shells and front and rear end heads for a shell and tube exchanger come in a range of types identified by
a letter, designated by TEMA
There are also some shell and tube type exchangers, such as double pipe and multi-tube, which are not
covered by TEMA
See also:
TEMA Shell Types
Shell&Tube Shell Diameters
Heat exchanger shells are normally manufactured from standard pipe for diameters up to 610 mm (24
inch) outside diameter, and from rolled plate thereafter. In theory, then, very large shell diameters are
possible. In practice, however, most exchanger manufacturers cannot handle or drill tubesheets greater

than approximately 3 meters (120 inches) in diameter and engineers contemplating shell sizes of this
order should always refer to prospective manufacturers for advice. At the other end of the scale heat
exchangers as small as 51 mm (2 inches) diameter with 6.35 mm (1/4 inch) tubes have been
manufactured. For exchangers with 19.05 mm (3/4 inch) tubes, 152 or 203 mm (6 or 8 inches) is usually
the minimum size shell used.
The size of pipe shells is clearly determined by the nominal size of available pipe - normally 152, 203,
254, 305, 356, 406, 457, 508 and 610 mm nominal bore (6, 8, 10, 12, 14, 16, 18, 20 and 24 inch). It is,
of course, the shell inside diameter (ID) that is of most interest to the thermal design engineer.
For standard wall pipe the IDs corresponding to the above nominal sizes are, respectively, 154, 203,
255, 305, 337, 387, 438, 489 and 591 mm (6.07, 7.98, 10.02, 12.00, 13.25, 15.25, 17.25, 19.25 and
23.25 inches).
For plate shells any diameter is possible but, in practice, design engineers tend to work in increments of
50 mm (e.g. 650, 700, 750 mm ID) or 2 inches (e.g. 26, 28, 30 inches ID).
See also:
Pass Arrangements
Shell&Tube Nozzles - Sizing
Generally speaking, heat exchanger design engineers will try to keep nozzle sizes as small as possible to
keep down costs. Wherever possible, this means that making the nozzle the same diameter as the
connecting pipework. It should be remembered, however, that any pressure loss in the nozzle can often
be more effectively used in the shell or the tubes and engineers should always check each run to ensure
that *P is not being 'wasted' in a nozzle when, for instance, it could be used to decrease the baffle pitch,
or increase the number of tube-passes.
If possible, nozzles which are very large compared to the shell (greater than one-third shell diameter)
should be avoided since these will require extensive re-enforcing and costly additional non-destructive
examination of the shell.
Where pressure drop is not a problem the minimum nozzle size is usually limited by the maximum
allowable fluid velocity. This is a metallurgical problem since excessive velocities can lead to erosion,
especially if the fluid contains solids in suspension. Clearly, the velocities which can be tolerated will be
much higher for gases than for liquids and it is more helpful to talk in terms of energy, or density times
velocity squared (* v2) rather than velocity. On this basis a safe upper limit for most fluids is around
9000 kg/ms2 (6000 lb/ft s2) and tube side nozzles should be sized such that this value is not exceeded.
See also:
Nozzles - TEMA Standards

Shell&Tube Tube Bundles
Ideally a tube bundle will occupy as much of the inside of the shell as possible, but in practice tubes will
be missing in a number of places.
1. Near the shell wall, particularly if there is a pull through floating head.
2. Next to the inlet nozzle, to give increased flow area (reduced velocity), or to give space for an
impingement plate under the nozzle.
3. In pass-partition lanes, corresponding to the position of the pass partition plates between passes, in the
front end or rear end heads.
In some positions tubes may be replaced by the tie rods that hold the baffles together.
The distance from the shell to the first tube row and to the last tube row define the size of the region
adjacent to the nozzle where tubes are not present.
Where tubes are missing, there can be flow paths whereby the fluid could bypass the bundle, with
adverse effects on the heat transfer. This can be particularly significant when the baffle cut is in line
with the nozzle, so tubes removed under the nozzle give a large bypass area. Bypass flows are reduced
by the use of sealing strips, between the bundle and the shell, and in any pass partition lanes which are
in-line with the main cross-flow direction.
For segmentally baffled exchangers, the bundle can be divided into two regions, the baffle overlap
region, where there is predominantly crossflow through the bundle, and the window flow region, where
the flow changes direction between one baffle space and the next.
A normal bundle is one with tubes removed next to nozzles. A full bundle is one with no such tubes
removed. In some exchangers, a reduced baffle cut is used, but there are No Tubes in the Window
(NTIW). Such designs have the advantage that all tubes are supported by every baffle, so the maximum
unsupported tube length is reduced, and with it the risk of vibration damage.
See also:
Tube Diameters
Shell&Tube Tube Diameters
TEMA section 'C lists nine standard tube outside diameters ranging from 6.35 to 50.8 mm (1/4 to 2
inch). Generally speaking tubes less than 12.7 mm (1/2 inch) are only used for small 'proprietary' type
exchangers and tubes greater than 25.4 mm (1 inch) would only be required for severely pressure drop

limited designs. The standard diameters in general use are, therefore, 12.7, 15.88, 19.05 and 25.4 mm
(1/2, 5/8, 3/4 and 1 inch).
The choice of diameter is usually based on established practice rather than the technical merits of any
particular case. Thus 12.7 and 15.88 mm tend to be specified in smaller exchangers for general industrial
use while, in the Process Industries it is established practice to use 19.05 mm tubes as standard with 25.4
mm being occasionally used for vertical thermosiphon reboilers and other services where tube side
pressure drop presents a problem.
There are several reasons why 19.05 mm tubes are by far the most commonly used in the Process
Industries:
19.05 mm is the smallest diameter recommended by section 'R' (the section applicable to petroleum
refineries) of the TEMA code
Tubes smaller than 19.05 mm OD tend to have inside diameters which make mechanical cleaning
difficult
Tube end welding of the smaller tubes is more difficult
The constraint imposed by the initial selection of a standard tube OD leads to a reduction in the man
hours required for design and cost estimation.
See also:
Tube Wall Thicknesses
Shell&Tube Tube Pattern and Tube Pitch
Tubes may range in diameter from 12.7 mm (0.5 in) to 50.8 mm (2 in) but 19.05 mm (0.75 in) and 25.4
mm (1 in) are the more common sizes. The tubes are laid out in triangular or square patterns in the tube
sheets.
There are four common patterns (sometimes called layouts).
Triangular: 30 degrees
Triangular: 60 degrees
Square: 45 degrees
Square: 90 degrees

The 90 degree pattern has tube rows ‘in-line’. The other layouts are ‘staggered’.
The square layouts permit access to tubes within the bundle for cleaning. Triangular layouts (with
conventional tube pitches) do not. With multiple passes, access to all the tubes within the bundle may
only be possible if the layouts within the various passes are aligned.
90 degree layouts are common in boiling applications such as kettles and flooded evaporators
30 degree layouts are more common than 60 degrees. The angles are usually defined relative to the flow
direction, but are sometimes referred to the vertical. Clarification may be needed in exchangers with a
vertical baffle cut, where the flow is side to side.
The triangular arrangement allows more tubes in a given space. The tube pitch is the shortest centre-to-
centre distance between tubes. The tube spacing is given by the tube pitch minus the tube diameter. The
tube pitch/tube diameter ratio is normally 1.25 or 1.33. Since a square layout is used for cleaning
purposes a minimum gap of 6.35 mm (0.25in) is allowed between tubes.
For assembly reasons a gap must exist between the outer tubes forming the bundle and the inside surface
of the shell (bundle to shell clearance). This gap depends upon the type of heat exchanger (fixed tube
sheet, U-tube or floating head). A larger gap is usually needed adjacent to the shell nozzles to avoid
excessive pressure drop (nozzle clearance). Tubes are either removed from the bundle opposite the
nozzles or a greater shell diameter is used at the nozzles, the latter is known as a vapor belt.
A larger tube-to-tube spacing is needed between tubes in adjacent passes, when there is more than one
pass. This is ‘pass partition gap’ is to allow for pass partition plates which are required to separate flows
in the channels
See also:
Tube Length - Maximum Value
Shell&Tube Tube Counts
The tube count is the total number of tubes in an exchanger. For this purpose, a U-tube is counted as
two-tubes, so the tube count still gives the total number of holes in the tubesheet.
Since tubes are laid out in a regular array, calculating the approximate number of tubes in an exchanger
is relatively straightforward. Allowance can be made for tubes removed adjacent to nozzles, pass
partition lanes etc. An exact tube count, however, can only be done when the position of every tube in
the exchanger is fixed, and allowance has to be made for tubes removed to give space for tie-rods.
Shell&Tube uses an approximate tube count in Design mode, but does an exact tube count in all other
modes.

The Tube Layout diagram in Shell&Tube shows you an exact tube count, and you can if you wish
modify this to correspond exactly to an exchanger you are modeling. You can do this by making sure
that all the Bundle Layout input items are set correctly, and then, if necessary, making additional
revisions by editing the diagram, by adding or deleting tubes, or moving tube-pass regions.
Alternatively you can explicitly specify a tube count in the input, and this value will be used in the heat
transfer and pressure drop calculations. If your specified value differs from the calculated value you will
get a warning. As long as the Tube Layout calculated by Shell&Tube more or less matches your
exchanger, using such a specified tube count should be a very good approximation, and will save you
the trouble of detailed editing of the diagram.
See also:
Baffle Types
Shell&Tube Baffle Types
Baffles are installed on the shell side for two reasons. Firstly they cause crossflow over the tube bundle,
and hence higher velocities and higher heat-transfer rates due to increased turbulence. Secondly they
support the tubes thus reducing the chance of damage due to vibration. There are a number of different
baffle types which give this turbulence due to crossflow:
Single Segmental Baffles
Double Segmental Baffles
Triple Segmental Baffles
Disc and Doughnut Baffles
The centre-to-centre distance between baffles is called the baffle-pitch or baffle spacing and this can be
adjusted to vary the crossflow velocity. In practice the baffle spacing is not normally greater than a
distance equal to the inside diameter of the shell or closer than a distance equal to one-fifth the diameter
or 50.8 mm (2 in) whichever is greater. In order to allow the fluid to flow backwards and forwards
across the tubes part of the baffle is cut away. The height of this part is referred to as the baffle-cut and
is measured as a percentage of the shell diameter, e.g. 25 per cent baffle-cut. The size of the baffle-cut
(or baffle window) needs to be considered along with the baffle spacing. It is normal to size the baffle-
cut and baffle spacing to equalize the velocities through the window an in crossflow respectively.
There are two main types of baffle which give longitudinal flow:

Orifice Baffles
Rod Baffles
In these types of baffle the turbulence is generated as the flow crosses the baffle.
Shell&Tube Quick Guide to Geometry Selection
The following is a quick guide on how exchanger geometry is selected
Tube outside diameter - for the process industry 19.05mm (3/4") tends to be the most common.
Tube wall thickness - there is not short cut for deciding this. Reference must be made to a recognized
pressure vessel code.
Tube length - for a given surface are the longer the tube length the cheaper the exchanger although a
long thin exchanger may not be feasible.
Tube Pattern (layout) - 45 or 90 degree patterns are chosen if mechanical cleaning is required otherwise
a 30 degree pattern is often selected because it provides a higher heat transfer and hence smaller
exchanger.
Tube pitch - the smallest allowable pitch of 1.25 times the tube outside diameter id normally used unless
there is a requirement to use a larger pitch due to mechanical cleaning or tube end welding.
Number of tube passes - is usually one or an even number (not normally greater than 16). Increasing the
number of passes increases the heat transfer coefficient but care must be taken to ensure that the tube
side rho-v2 is not greater than about 10 000 kg/m s2
Shell diameter - standard pipe is normally used for diameters up to 610mm (24"). Above this they are
made from rolled plate. Typically shell diameters range from 152 mm to 3000 mm (6" to 120").
Baffle type - single segmental are used by default with other types being considered if pressure drop
constraints or vibration is a problem.
Baffle spacing - this is decided after trying to balance the desire for increased crossflow velocity and
tube support (smaller baffle pitch) and pressure drop constraints (larger baffle pitch). TEMA provides
guidance on the maximum baffle pitch and the absolute minimum baffle pitch is about 50 mm (2").
Baffle cut - this depends on the baffle type but is typically 45% for single segmental baffles and 25% for
double segmental baffles.
Nozzles and impingement protection - for shell side nozzles the rho-v2 should not be greater than about
9000 in kg/m s2. For tube side nozzles the maximum rho-v2 should not exceed 2230 kg/m s2 for non-
corrosive, non-abrasive single phase fluids and 740 kg/m s2 for other fluids. Impingement protection is

always required for gases which are corrosive or abrasive, saturated vapors and two phase mixtures.
Shell or bundle entrance or exit areas should be designed such that a rho-v2 of 5950 kg/m s2 is not
exceeded.
Shell&Tube TEMA
TEMA is the U.S. Tubular Exchanger Manufacturers' Association, which produces a regularly updated
set of standards, relating (primarily) to mechanical design considerations for shell and tube heat
exchangers.

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Shell&Tube Thermal Design of Shell & Tube Heat Exchangers Page 1 of 47

Shell&Tube Thermal Design of Shell & Tube

Shell&Tube Getting Started Guide

Shell and Tube Heat Exchanger Geometry

Quick Guide to Geometry Selection

Physical Property Data

Stream Properties – Property Databanks, Stream Definition, Property Tables

Geometry Summary – Geometry, Tube Layout

Shell/Heads/Flanges/Tubesheets – Shell/Heads, Covers, Tubesheets, Flanges

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Baffles/Supports – Baffles, Tube Supports, Longitudinal Baffles, Variable Baffle Pitches

Nozzles – Shell Side Nozzles, Tube Side Nozzles, Domes/Belts, Impingement

Materials of Construction – Vessel Materials, Cladding/Gasket Materials, Tube Properties

Thermal Analysis – Heat Transfer, Pressure Drop, Delta T, Fouling

Methods/Correlations – General, Condensation, Vaporization, Enhancement Data

Calculation Options – Calculation Options

Shell&Tube Problem Definition

TEMA Specification Sheet Descriptions

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Shell&Tube Application Options

Location of Hot Fluid

Select Geometry based on this Dimensional Standard

Thermosiphon Circuit Calculation

Shell&Tube Process Data

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Mass Flow Rate

Vapor Mass Fraction

Pressure at Liquid Surface in Column

Estimated Pressure Drop

Allowable Pressure Drop

Physical Property Data Overview

The following property package options are available:

User Specified Properties

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The Properties section includes the following screens:

Refrigerant Cross Referencing Table

Shell&Tube Exchanger Geometry

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Shell&Tube Geometry Summary

The Shell/Heads/Flanges/Tubesheets section includes the following screens:

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KHT Twisted Tubes

Variable Baffle Pitches

Shell&Tube Bundle Layout

Layout Limits/Pass Lanes

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Shell Side Nozzles

Tube Side Nozzles

Shell&Tube Thermosiphon Piping

Inlet Piping Elements

Outlet Piping Elements

Shell&Tube Construction Specifications

Shell&Tube Materials of Construction

Shell&Tube Design Specifications

Shell&Tube Program Options

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The Program Options section includes the following screens:

Shell&Tube Design Options

Shell&Tube Thermal Analysis

The Thermal Analysis section includes the following screens:

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Shell&Tube Calculation Options

Maximum Number of Iterations