ELEMAN

Newbie Group: Members Posts: 7 Member No.: 7,154 Joined: 3-May 07

Dimetro y longitu Buenas tardes Art: Espero que al leer estas lneas se encuentre bien al lado de los suyos.

En esta ocasin vuelvo sobre el tema de la sedimentacin de slidos y el asentamiento de a pesado almacenado en tanques sobre el suelo.

Para provocar el asentamiento de agua y partculas slidas en el tanque de almacenamiento serpentn (bobina o coil). Habiendo analizado la Ley de Stokes vemos que, la velocidad d funcin directa tanto de la viscosidad como de la densidad del fluido y, ambas varan con l decidido tratar de acelerar ese proceso alimentando ms calor para elevar la temperatura Los datos de los clculos que he realizado con un tanque lleno son:

Tanque desnudo (sin aislamiento trmico), cerrado con techo fijo y tiene respirader Dimetro del tanque: 16.8 m Altura del tanque: 9.1 m Altura de llenado mximo (por seguridad): 8 m Espesor promedio de la chapa del tanque: 0,0079 m Temperatura ambiente: 35 C El viento es calmo (casi esttico) Temperatura inicial del combustible: 40 C Temperatura final del combustible: 65 C Volumen de combustible (tanque lleno): 1,800 m Densidad del combustible: 998 kg/m @ 15 C Viscosidad del combustible: 635 cSt @ 50 C Calor especfico del combustible: 2,1 kJ/kg K Tiempo de calentamiento: 24 horas Presin del vapor antes de vlvula reguladora: 6,5 barg y T = 170 C Presin del vapor despus de vlvula reguladora: 4,35 bara y T = 147 C

El tanque al inicio del llenado tendr un volumen muerto (inextrable) de 130 m a una tem de llenado es 210 m/h de combustible a 40 C. Tiempo de llenado 8 horas.

Despus de llenado el tanque, el combustible reposa (no entra ni sale producto del tanque) 50 horas, este tanque comienza a ser vaciado. El resultado final que obtengo para este escenario es: rea de transferencia de calor requerida: 261 m Dimetro del serpentn: 162 mm (arriba de 6") Longitud: 495 m

Tambin hice un clculo para 36 horas de calentamiento y me da un dimetro 128 mm (red

50 horas, este tanque comienza a ser vaciado. El resultado final que obtengo para este escenario es: rea de transferencia de calor requerida: 261 m Dimetro del serpentn: 162 mm (arriba de 6") Longitud: 495 m

Tambin hice un clculo para 36 horas de calentamiento y me da un dimetro 128 mm (red Como podr usted ver Art, el tiempo de reposo para el asentamiento es el que me obliga a el menor tiempo posible.

Despus de toda esta exposicin, las preguntas que me agobian son existen en la industria aplicaciones reales de serpentines de este dimetro y de esta longitud? Estoy calculando los tubos en forma de retcula cmo instalar tantos tubos en un tanque de 16,8 m de dim Art, espero en esta ocasin no haber abusado de su confianza y, despus de que analice lo sus comentarios al respecto. Atentamente ELEMAN

Dimetro y longitud de serpentn

Personal Message ELEMAN Newbie Estimado Art:
Group: Members Posts: 7 Member No.: 7,154 Joined: 3-May 07

Dimetro y longitud de s

Pido un milln de disculpas por no poner en mi carta datos importantes que us para los clculos Calor requerido: 1,723 kW Calor latente de vaporizacin: 2,126 kJ/kg Flujo msico de vapor: 2,918 kg/h

Gracias por su comprensin. ELEMAN

Consulta no atendida
Personal Message ELEMAN
Newbie Group: Members Posts: 7 Member No.: 7,154 Joined: 3-May 07

Consulta no atendi

Buenas tardes Art:

El 1 de Octubre recin pasado le envi una consulta sobre el clculo de un serpentn para calenta

Conociendo lo diligente de su accionar en los foros en que participa, me parece un tanto raro que sobre el trabajo que hice. Yo me pregunto hice algo malo al preguntar en forma privada y no en clculos que no vale la pena ni contestar? No soy tan hbil al preguntar si una tubera de dime un haz de tubos de dimetro menor? En este ltimo caso, no creo que sea eso porque en los foro

Personal Message ELEMAN

Newbie Group: Members Posts: 7 Member No.: 7,154 Joined: 3-May 07

Consulta no atendi

Buenas tardes Art:

El 1 de Octubre recin pasado le envi una consulta sobre el clculo de un serpentn para calenta

Conociendo lo diligente de su accionar en los foros en que participa, me parece un tanto raro que sobre el trabajo que hice. Yo me pregunto hice algo malo al preguntar en forma privada y no en clculos que no vale la pena ni contestar? No soy tan hbil al preguntar si una tubera de dime un haz de tubos de dimetro menor? En este ltimo caso, no creo que sea eso porque en los foro bien una pregunta, usted la recompone en la forma como debiera hacerse la pregunta y, en base a Estoy un tanto desconcertado por su silencio, por ello mucho le agradecer me seale mi error o cerrar el tema. Reciba un saludo fraterno ELEMAN

Re:Consulta no atendida
Personal Message Art Montemayor
ChE Jedi Group: Admin Posts: 1,025 Member No.: 4 Joined: 8-March 03

Re:Consulta no atendida, Oct 18 2007, 11:28 AM ELEMAN: Lamento que aunque le tus mensajes, no les di prioridad ya que no me indicaste que era urgente el contestarte y, como me ha estado pasando frecuentemente, simplemente me olvide. Te pido mil disculpas y ojala no te he causado algn dao en tus necesidades. Como he estado renovando nuestra residencia - especialmente la cocina de mi seora - me ha costeado bastante tiempo y preocupacin los proyectos que tengo en casa. Sin embargo, tengo respuesta(s) a tu solicitud. 1. No me parece prctico lo que t propones. Aunque no lo dices abiertamente, lo que entiendo segn tu descripcin del proceso, t propones hacer un calentamiento tipo batch en el tanque de almacenamiento. Este es el tipo de calefaccin ms ineficiente y yo no lo respaldo porque es dificilsimo disear este tipo de proceso - adems de costoso, como te habrs dado cuenta. 2. La forma que yo lo hara es con un intercambiador tipo TEMA, con los espejos fijos. El vapor en la carcaza y el petrleo en los tubos, con pasos mltiples en los tubos. Yo calentara el petrleo mientras lo bombeas al tanque y tomo provecho del cabezal de la bomba para lograr una cada de presin a travs del calentador. Es as que puedo disminuir el rea requerida para lograr la transferencia de calor. Yo calculo (a grosso modo) que una rea de aproximadamente 700 pies cuadrados seria suficiente. T calculas 2, 800 pies cuadrados. Como no mandaste tus clculos, no se tu forma y base de clculos. Propongo que solicites a travs del Foro solucin a tu problema y all te puedo contestar todos los detalles que necesites. Inclusive, te envo a travs del Foro mis clculos en forma de Excel - conjuntamente con todas las explicaciones de los clculos. Tengo mucho por decir y explicar sobre esta aplicacin, pero no tengo el tiempo en este momento. Espero tu respuesta.

Yo calculo (a grosso modo) que una rea de aproximadamente 700 pies cuadrados seria suficiente. T calculas 2, 800 pies cuadrados. Como no mandaste tus clculos, no se tu forma y base de clculos. Propongo que solicites a travs del Foro solucin a tu problema y all te puedo contestar todos los detalles que necesites. Inclusive, te envo a travs del Foro mis clculos en forma de Excel - conjuntamente con todas las explicaciones de los clculos. Tengo mucho por decir y explicar sobre esta aplicacin, pero no tengo el tiempo en este momento. Espero tu respuesta. Ojala esto te ayude en tu proyecto. Saludos.

Heating Of Heavy Fuel Oil

ELEMAN
Newbie Group: Members Posts: 8 Joined: 3May 07 Member No.: 7,154

Oct 19 2007, 09:15 AM IP: 63.245.9.171 Post #1 Hello everybody: In order to obtain some sedimentation and/or settling of solids and water contained in heavy fuel oil (Bunker C or distillate #6), we are planning to heat this fuel oil in their above ground uninsulated storage tanks. The heating fluid available is saturated steam that would be feeded to an immersed steam coil in the tanks. We plan to fill up these tanks and then, supply the heat. The tanks are uninsulated, with fixed and vented roof. Tanks diameter: 16,8 m Tanks height: 9,1 m Maximum level of fuel in the tanks: 8 m Average tank plate thickness: 0,0079 m Ambient temperature: 35 C The wind in the tank farm area is still Initial temperature of fuel in the tanks: 40 C Final temperature of fuel in the tanks: 65 C Initial volume of fuel in the tank: 130 m at T = 65 C Final volume of fuel in the tank: 1,800 m at T ~ 40 C Mass flow rate of filling up: 210 m/h at T = 40 C Time for filling up: ~ 8 hours Density of the fuel oil: 998 kg/m @ 15 C Kinematics viscosity of the fuel: 635 cSt @ 50 C Specific heat of the fuel: 2,1 kJ/kg K Heating time: 24 hours Steam pressure before regulating valve: 6,5 barg @ 168 C Steam pressure after regulating valve: 4,35 bara @ 147 C

After the filling up is achieved, the fuel remains at rest (no fuel in and no fuel out of the tank) for 50 hours. At the end of this settling time, the tank starts to be emptied. From my calculations I have this: Heat required: 1.723 kW Latent heat of vaporization: 2,126 kJ/kg Steam mass flow rate: 2,918 kg/h

Steam pressure before regulating valve: 6,5 barg @ 168 C Steam pressure after regulating valve: 4,35 bara @ 147 C

After the filling up is achieved, the fuel remains at rest (no fuel in and no fuel out of the tank) for 50 hours. At the end of this settling time, the tank starts to be emptied. From my calculations I have this: Heat required: 1.723 kW Latent heat of vaporization: 2,126 kJ/kg Steam mass flow rate: 2,918 kg/h Heat transfer area: 261 m Steam coil diameter: 162 mm (more than 6") Steam coil length: 495 m

For a heating time of 36 hours, the coil diameter is 128 mm and length of 371 m. The maximum settling time of 50 hours obliges to heat the fuel oil to 65 C in a very short time. I am surprised with those dimensions of the steam coils. Please submit your comments regarding to this subject. Thanks in advance.

Dimetro y longitud de serpentn, Oct 1 2007, 03:58 PM

os suyos. slidos y el asentamiento de agua contenidos en combustible

n el tanque de almacenamiento, se alimenta vapor a travs de un kes vemos que, la velocidad de precipitacin de los slidos es el fluido y, ambas varan con la temperatura. Por ello, hemos alor para elevar la temperatura del combustible en los tanques.

no son:

on techo fijo y tiene respiradero.

0.0079 meters =

o 40 C = o 65 C =

arg y T = 170 C 5 bara y T = 147 C

o 170 C = o 147 C =

extrable) de 130 m a una temperatura de 65 C. El flujo msico lenado 8 horas.

ra ni sale producto del tanque) por 50 horas. Una vez cumplidas las

t1 = t2 = T1 = T2 = Dt1 = Dt2 =

me da un dimetro 128 mm (redondeado a 6") y longitud de 371 m.

2 261 M =

Q = 5,879,120 Q = UA DT U = DT = A = 50 173.803 676.527

me da un dimetro 128 mm (redondeado a 6") y longitud de 371 m.

amiento es el que me obliga a alcanzar la temperatura de 65 C en

ian son existen en la industria y en las plantas de generacin longitud? Estoy calculando mal mi serpentn? An disponiendo n un tanque de 16,8 m de dimetro?

a y, despus de que analice lo aqu expuesto, mucho le agradecer

Dimetro y longitud de serpentn, Oct 1 2007, 04:05 PM

rtantes que us para los clculos.

Consulta no atendida, October 17, 2007; 05:44 PM

ulo de un serpentn para calentamiento con vapor.

ipa, me parece un tanto raro que no haya dado una opinin eguntar en forma privada y no en el foro? Estn tan malos los reguntar si una tubera de dimetro grande puede sustituirse por o que sea eso porque en los foros cuando alguien no formula

Consulta no atendida, October 17, 2007; 05:44 PM

ulo de un serpentn para calentamiento con vapor.

ipa, me parece un tanto raro que no haya dado una opinin eguntar en forma privada y no en el foro? Estn tan malos los reguntar si una tubera de dimetro grande puede sustituirse por o que sea eso porque en los foros cuando alguien no formula hacerse la pregunta y, en base a ello usted da su opinin.

agradecer me seale mi error o errores y ello me bastar para

da, Oct 18 2007, 11:28 AM

ue no me indicaste que era mente, simplemente me

us necesidades. Como he de mi seora - me ha ngo en casa. Sin embargo,

lo dices abiertamente, lo ones hacer un iento. Este es el tipo de es dificilsimo disear este ado cuenta.

TEMA, con los espejos con pasos mltiples en los l tanque y tomo provecho n a travs del calentador. r la transferencia de calor. damente 700 pies drados. Como no os.

a y all te puedo contestar el Foro mis clculos en e los clculos.

no tengo el tiempo en este

damente 700 pies drados. Como no os.

a y all te puedo contestar el Foro mis clculos en e los clculos.

no tengo el tiempo en este

M IP: 63.245.9.171 Post #1

and water contained in at this fuel oil in their lable is saturated steam

C C

in and no fuel out of the rts to be emptied.

C C

in and no fuel out of the rts to be emptied.

d length of 371 m.

oil to 65 C in a very coils. Please submit your

5/16

inches

o 104 F o 149 F

o 338 F o 297 F o o

100 150 300 300

F F o F o F

o 200 F o 150 F

2,809 Btu/hr

ft2

Btu/hr-ft2-oF F ft2

Temperature, oF

297 149

104 Distance along tubes

Steam pressure before regulating valve: Steam temperature before regulating valve: Steam pressure after regulating valve:

6.5 bara = o 168 C = 4.35 bara = o 147 C = 1,179.90 Btu/lb 266.82 Btu/lb 913.08 Btu/lb

94.3 psia o 334 F 63.1 psia o 297 F (NIST Database) (NIST Database) (NIST Database)

Saturated vapor enthalphy at 297 oF & 64.071 psia = Saturated liquid enthalphy at 297 F & 64.071 psia = Latent Heat of Condensation = Inlet Temperature of oil = Outlet Temperature of oil =
o 104 F o 149 F o

Heater Duty = 5,879,120 Btu/hr = Steam Flow Rate = 6,439 lb/hr = Heater Heat Transfer Area Required = Quantity of 1" O.D. tubes Required = Quantity of 20 foot tube lengths = Estimated Steam heater size is: Shell O. D. = Shell Length = Steam shell passes = Oil Tube passes = One Four

1,723 kW 2,921 kg/hr 2 694 ft 2,650 linear feet (14 BWG wall thickness) 132 tubes

22 inches = 20 ft

55.88 cm 6.1 meters

(estimated; based on getting good tube velocity)

Art's data from NIST database (assuming saturated conditions) 6.5 bara o 161.98 C (this means Eleman's data is slightly superheated) 4.35 bara o 146.66 C

(this means Eleman is assuming that the flash product will approximate saturated conditions; he's correct)

Heating Of Heavy Fuel Oil

ELEMAN
Newbie Group: Members Posts: 8 Joined: 3May 07 Member No.: 7,154

Oct 19 2007, 09:15 AM IP: 63.245.9.171 Post #1 Hello everybody: In order to obtain some sedimentation and/or settling of solids and water contained in heavy fuel oil (Bunker C or distillate #6), we are planning to heat this fuel oil in their above ground uninsulated storage tanks. The heating fluid available is saturated steam that would be feeded to an immersed steam coil in the tanks. We plan to fill up these tanks and then, supply the heat. The tanks are uninsulated, with fixed and vented roof. Tanks diameter: 16,8 m Tanks height: 9,1 m Maximum level of fuel in the tanks: 8 m Average tank plate thickness: 0,0079 m Ambient temperature: 35 C The wind in the tank farm area is still Initial temperature of fuel in the tanks: 40 C Final temperature of fuel in the tanks: 65 C Initial volume of fuel in the tank: 130 m at T = 65 C Final volume of fuel in the tank: 1,800 m at T ~ 40 C Mass flow rate of filling up: 210 m/h at T = 40 C Time for filling up: ~ 8 hours Density of the fuel oil: 998 kg/m @ 15 C Kinematics viscosity of the fuel: 635 cSt @ 50 C Specific heat of the fuel: 2,1 kJ/kg K Heating time: 24 hours Steam pressure before regulating valve: 6,5 barg @ 168 C Steam pressure after regulating valve: 4,35 bara @ 147 C

After the filling up is achieved, the fuel remains at rest (no fuel in and no fuel out of the tank) for 50 hours. At the end of this settling time, the tank starts to be emptied. From my calculations I have this: Heat required: 1.723 kW Latent heat of vaporization: 2,126 kJ/kg Steam mass flow rate: 2,918 kg/h Heat transfer area: 261 m Steam coil diameter: 162 mm (more than 6") Steam coil length: 495 m

For a heating time of 36 hours, the coil diameter is 128 mm and length of 371 m. The maximum settling time of 50 hours obliges to heat the fuel oil to 65 C in a very short time. I am surprised with those dimensions of the steam coils. Please submit your comments regarding to this subject.

Steam mass flow rate: 2,918 kg/h Heat transfer area: 261 m Steam coil diameter: 162 mm (more than 6") Steam coil length: 495 m

For a heating time of 36 hours, the coil diameter is 128 mm and length of 371 m. The maximum settling time of 50 hours obliges to heat the fuel oil to 65 C in a very short time. I am surprised with those dimensions of the steam coils. Please submit your comments regarding to this subject. Thanks in advance.

M IP: 63.245.9.171 Post #1

s and water contained in heat this fuel oil in their ailable is saturated steam

68 C 7 C

el in and no fuel out of the arts to be emptied.

nd length of 371 m.

el oil to 65 C in a very m coils. Please submit your

nd length of 371 m.

el oil to 65 C in a very m coils. Please submit your

Art Montemayor

September 30, 2005 Rev: 0

TEMA DESIGNATIONS
Front End Stationary Head Shell Type Rear End Stationary Head

Channel and removable cover

One-pass shell

Fixed tubesheet; like "A" Stationary head.

Bonnet (Integral Cover)

2-pass shell with longitudinal baffle

Fixed tubesheet; like "B"

stationary head.

C Channel integral with tubesheet

& removable cover. Shown: Removable Tube Bundle

Split Flow Shell

Fixed tubesheet; like "C" stationary head.

Channel integral with tubesheet & removable cover.

Double split flow

Outside, packed floating head

Page 21 of 46

FileName: 186985106.xls.ms_office WorkSheet: TEMA Designations

Art Montemayor

September 30, 2005 Rev: 0

Special, high-pressure closure

Divided shell flow

Floating head with backing device (split-ring)

Conventional Front End Heads:

A
or,

B K
Other popular rear end head types employed:

Kettle type of reboiler

Pull-through floating head

U-tube bundle design (No Rear Head Required)

W Packed floating tubesheet with

lantern ring

Page 22 of 46

FileName: 186985106.xls.ms_office WorkSheet: TEMA Designations

Art Montemayor

Some examples of the TEMA designation for Heat Exchangers are shown below:

September 30, 2005 Rev: 0

BEM

Front bonnet (Intergral Cover), with one-Pass Shell and a Fixed Tubesheet rear Bonnet

Fixed tubesheet heat exchanger. This is a very popular version as the heads can be removed to clean the inside of the tubes. The front head piping must be unbolted to allow front head removal; if this is undesirable, then this can be avoided by applying a type A front head. In that case only the cover needs to be removed. It is not possible to mechanically clean the outside surface of the tubes as these are fixed inside the shell. Chemical cleaning can be used in the shell side. Shown is a version with one shell pass and two tube passes. This is probably the least expensive of the shell-and-tube designs.

BEM

This is the same type of heat exchanger as shown above, except it has only one tube pass

AEM

Channel with Removable Cover, One Pass Shell, Fixed Tubesheet Bonnet

This is almost the same type of heat exchanger as the first BEM. The removable cover allows the inside of the tubes to be inspected and cleaned without unbolting the piping. However, as can be expected, the tradeoff is that this convenient feature makes it more expensive.

Page 23 of 46

FileName: 186985106.xls.ms_office WorkSheet: TEMA Designations

Art Montemayor

The maintenance feature of having a removable tube bundles requires an exchanger

September 30, 2005 Rev: 0 as the following:

AES

Channel and Removable Cover, One Pass Shell, Floating Head with Backing Device

A floating head heat exchanger is excellent for applications where the difference in temperature between the hot and cold fluid causes unacceptable stresses in the axial direction, between the shell and tubes. The floating head can move, i.e. it provides the ability to allow tube expansion in the axial direction. Note that the bundle can not be pulled from the front end. For maintenance both the front and rear end head, including the backing device, must be disassembled. If pulling from the front head is required a type AET should be selected. However, it is wise and prudent to be aware of the inherent trade-offs in this design. Note that the tube-side fluid can leak through the internal floating head cover gasket and mix (or contaminate) the shell-side fluid. It is very difficult -and sometimes impossible to mitigate or compensate for the internal bolts tightening the internal bonnet to remain under constant, steady torque. Hot fluid temperatures make the bolts expand and the result is a reduction in bolt torque and subsequent leaks through the bonnet gasket. Additionally, it is a common and expected occurance for maintenance crews to find the internal bolts badly rusted or corroded to the point where they have to be burned or sawed off in order to extract the "removable" tube bundle. The chemical engineer has other options to apply when requiring mechanical expansion of a heat exchanger tube bundle. Various rear head design also exist that allow for tube bundle expansion. Among these are the popular (and inexpensive) "U" tube bundle design. A "P" and "W" rear head design will also contribute this feature without the hazard of internal mixing (or contamination) of the two fluids. Also, be aware that any TEMA shell and tube design with a removable tube bundle feature has - by nature - a larger shell diameter (& increased cost) due to the need to be able to pull the rear tubesheet the length of the exchanger's shell. A larger diameter shell can sometimes also present problems in a lower Reynolds number (yielding a lower heat transfer) and internal by-passing of the shell fluid around the baffles (this also reduces the effective heat transferred. All these effects eventually lead to a bigger heat exchanger (more area and more tubes) in order to do a heat transfer operation.

Page 24 of 46

FileName: 186985106.xls.ms_office WorkSheet: TEMA Designations

Art Montemayor

September 30, 2005 Rev: 0

Longitudinal Baffles - their application and inherent problems

The employment of longitudinal baffles in heat exchangers - such as the "F", "G", and "H" shell types - can often resolve both heat transfer and fluid flow problems within the shell and tube exchanger used. Their application can significantly increase the shell-side Reynolds Number and lead to more efficient shell-side heat transfer coefficients with a subsequent increase in heat transfer. Additionally, these type of baffles permit the engineer to incorporate counter-flow heat transfer. True counter-current heat transfer is as efficient a heat transfer configuration as an engineer can obtain. In some heat recovery applications, this is highly sought. By splitting the shell-side flow, some applications can actually have a significant reduction in shell-side pressure drop. This is especially true in partial vacuum process operations where a minimum of pressure drop can be tolerated. However, the application of longitudinal baffles should be always carefully scrutinized and used sparingly. There are, as would be expected, some very important trade-offs involved in the application of longitudinal baffles. Firstly, if a longitudinal baffle is a process necessity, the baffle should be seal-welded against the inner shell wall in order to ensure that there will be no internal, by-pass leakage. This positive step negates the possibility of having a removable tube bundle. Additionally, the welding necessity requires a minimum shell diameter and this winds up being applicable only to relatively large streams. By the basic need to establish effective shell-side flow around a longitudinal baffle, one has to accept the obvious fact that a minimum of shell-side clearances can be tolerated. Once having said and applied these facts, one then has to also accept that the required, small baffle clearances mean extraordinary fabrication techniques and resultant super-human maintenance efforts to extract a removable tube bundle. In far too many actual field cases, it has been found that the removable tube bundle with a longitudinal baffle is a non-practical device. Field results have shown that in most cases the tube bundle has resulted in being destroyed in order to remove it. This extraordinary and desperate maintenance act labels such a design as non-practical.

Page 25 of 46

FileName: 186985106.xls.ms_office WorkSheet: TEMA Designations

Art Montemayor

September 30, 2003 Rev: 0

Heat Exchanger Tube Sheet Layout Count Table

Source: "Applied Process Design for Chemical and Petrochemical Plants"; Vol. 3; p.24 Ernest E. Ludwig; Gulf Publishing Co.; Houston, TX (1965)

Shell I. D., inches

Tube O. D. & Pitch
Fixed Tubes Fixed Tubes 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square 3/4" on 15/16" Triang. 3/4" on 1" Triang. 3/4" on 1" Square 1" on 1-1/4" Triang. 1" on 1-1/4" Square One-Pass 8 33 33 33 15 17 32 28 26 16 12 8 8 12 XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX XX 10 69 57 53 33 33 58 56 48 32 26 34 26 30 8 12 48 44 48 24 24 28 20 24 12 13-1/4 15-1/4 17-1/4 19-1/4 21-1/4 23-1/4 105 135 193 247 307 391 481 91 117 157 217 277 343 423 85 101 139 183 235 287 355 57 73 103 133 163 205 247 45 65 83 111 139 179 215 94 90 78 52 40 64 60 52 26 22 84 72 72 44 40 56 52 44 20 16 124 110 94 62 56 94 72 72 42 38 108 96 88 60 48 84 64 64 36 32 80 66 54 34 74 56 56 30 166 154 126 92 76 134 108 100 58 58 154 134 126 78 74 122 98 90 50 50 116 104 78 56 44 110 88 80 42 42 94 82 228 208 172 126 106 180 158 142 84 76 196 180 142 104 84 166 146 130 74 66 174 156 116 82 66 156 134 118 68 60 140 124 94 66 142 122 106 58 50 300 264 222 162 136 234 212 188 120 100 266 232 192 138 110 218 198 174 110 90 230 202 158 112 88 206 184 160 100 80 198 170 132 90 74 190 170 146 90 70 370 326 280 204 172 304 270 242 154 134 332 292 242 176 142 286 254 226 142 122 294 258 212 150 116 272 268 210 130 110 258 224 174 120 94 254 226 194 118 98 452 398 346 244 218 398 336 304 192 180 412 360 308 212 188 378 318 286 178 166 372 322 266 182 154 358 300 268 168 152 332 286 228 154 128 342 286 254 154 142 25 553 493 419 307 255 528 468 408 292 248 460 406 362 234 214 484 424 366 258 214 438 386 342 218 198 440 388 324 226 184 416 366 322 206 182 398 344 286 190 150 398 350 306 190 170 27 663 577 495 361 303 626 556 486 346 298 558 484 436 284 256 576 508 440 308 260 534 462 414 266 238 532 464 394 274 226 510 440 392 252 224 484 422 352 240 192 490 422 374 238 206 29 763 667 587 427 359 734 646 560 410 348 648 566 506 340 304 680 596 510 368 310 622 542 482 322 286 632 548 460 338 268 596 518 458 304 268 576 496 414 298 230 578 498 438 290 254 31 881 765 665 481 413 846 746 644 462 402 768 674 586 396 356 788 692 590 422 360 740 648 560 376 336 732 640 536 382 318 716 626 534 356 316 682 588 490 342 280 688 600 512 340 300 33 1,019 889 765 551 477 964 858 746 530 460 882 772 688 466 406 904 802 688 486 414 852 744 660 444 384 844 744 634 442 368 826 720 632 426 362 790 694 576 400 334 796 692 608 404 344 35 1,143 1,007 865 633 545 1,088 972 840 608 522 1,008 882 778 532 464 1,024 912 778 560 476 976 852 748 508 440 964 852 224 514 430 944 826 718 488 420 902 798 662 466 388 916 796 692 464 396 37 1,269 1,127 965 699 595 1,242 1,088 946 688 584 1,126 1,000 884 610 526 1,172 1,024 880 638 534 1,092 968 852 584 500 1,106 964 818 586 484 1,058 940 820 562 478 1,040 902 760 542 438 1,032 908 792 540 456

Two-Pass Four-Pass Six-Pass Eight-Pass

Fixed Tubes

U Tubes

Fixed Tubes

U Tubes

Fixed Tubes

U Tubes

Notes: 1) The above tube counts have an allowance made for Tie Rods. 2) The Radius of Bend for the U-Tube bundles is equal to (2.5) (Tube O.D.); The actual number of U-tubes is 1/2 of the above figures. Page 26 of 46

U Tubes

68 52 48 24

102 82 70 38 34

FileName: 186985106.xls.ms_office WorkSheet: Tube Counts

Art Montemayor

Heat Exchanger Estimate HEAT EXCHANGER SUMMARY

August 21, 1998 Rev: 0

T in, Cold Side (t1) T out, Cold Side (t2) T in, Hot Side (T1) T out, Hot Side (T2) Exchanger Heat Duty Overall U estimated Number of shell passes Number of tube passes Log Mean Temperature Difference, LMTD F Factor (See Calcs below) Adjusted LMTD Heat Transfer Area calculated Design Contingency Factor Over Design Factor Total Heat Transfer Area Required 450 psig, Saturated Steam Req'd, CW Req'd @ 45 deg rise, gpm

104 149 297 297 5,879 50 1 4 170 1.00 170 694 1.10 1.00

o o o o

F F F F

M Btu/hr Btu/hr - Ft2 - oF

F Ft2

2 763 Ft

7,685 lbs/hr 261 gpm

Calculation of F Factor: P (or S) R Term 1 Px Term 2 Term 3 Term 4A Term 4B Term 4 F

0.23 0.00 1.30 [(RP-1)/(P-1)]^(1/N) 0.23 -1.00 (R^2+1)^0.5/(R-1) -0.27 0.77 8.58 6.58 0.27 1.00

Page 27 of 46

FileName: 186985106.xls.ms_office WorkSheet: HX DESIGN

Corporation Lean MEA Solution Cooler Km 8, Avda. Venezuela; Lima, Peru Model 3 Manufacturer *
1 Service 2 Location 4 TEMA Size, Type 5 Surface/Unit 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 P&ID No. Fluid Allocation Fluid Circulated Total Fluid Entering Vapor (In/Out) Liquid Steam Non-Condensables Fluid Vaporized or Condensed Steam Condensed Temperature Density, Specific Gravity Viscosity Vapor Molecular Weight Specific Heat Thermal Conductivity Latent Heat Operating Pressure, Inlet Velocity Max. Min. Pressure Drop, Clean (Allow./Calc.) Fouling Resistance Heat Exchanged Transfer Rate, Service Horiz. Unit

Project No.
Equipment No.

*
Vert.

German Huanuco P.O. No. Mfr Ref. No. *

Connected in Series

No. Req'd Parallel ft2 Gross Eff.

ft2

Gross

Eff.

Shells/Unit

One

Surface/Shell

Plot Plan No. PERFORMANCE OF ONE UNIT SHELL SIDE lb/h lb/h lb/h lb/h lb/h lb/h lb/h F cP

Other Ref. Dwg No. TUBE SIDE

Btu/lbF Btu/hftF Btu/lb psig fps psi ft2hF/Btu . Btu/h Log MTD (Uncorrected) F Log MTD (Corrected) * * Btu/ft2hF . Transfer Rate, Clean CONSTRUCTION AND MATERIALS SHELL SIDE TUBE SIDE Sketch (Bundle, Nozzle Orientation)

* F Btu/ft2hF .

Design Pressure psig Test Pressure psig Design Temperature F Number of Passes per Shell In Connections Out Size & Rating Intermediate * 0.75 16 BWG or 30 Tubes: Type Number OD in. in. X Min. 45 60 90 Av. Wall 0.9375 Tube Length in. Tube Pitch in. Flow Pattern (circle one) * * Rolled and Seal Welded Shell: ID in. OD in. Tube-to-Tubesheet Joint * * * Baffles - Cross: Type Spacing in. % Cut on Area X Diam. Baffles - Long: Perm. Removable Seal Type: Bypass Seal: * * * lb/ftsec Bundle Entrance lb/ftsec Bundle Exit lb/ftsec rv2: Inlet Nozzle Expansion Joint? Yes Type: Impingement Protection? No X No X Yes PART THK, in. C.A., in. PART THK, in. C.A., in. MATERIAL MATERIAL Stainless Stl 16 BWG min. * ---Tubes Floating Tubesheet Carbon Steel Carbon Steel Shell Fixed Tubesheet * 0.125 Carbon Steel Shell Cover Tube Supports * 0.125 Carbon Steel Channel Cross Baffles * 0.125 Bronze Channel Cover Long Baffle * 0.125 Stainless Stl ---Fltg Head Cover Gaskets User Spec.: Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts Yes TEMA Class: Code Requirements: Stamp? ASME Sec. VIII, Para. 1 (1992) * * * Weights: Shell lb Filled with Water lb Bundle lb Remarks 1. Items marked with an asterisk (*) to be completed by Vendor.

Rev 0

Date

Description For Purchase

By

Chk.

Appr.

Rev

Date

Description

By

Chk.

Appr.

Rev. No.

Montemayor

SHELL & TUBE HEAT EXCHANGER SPECIFICATION (English Units)

Sheet

1 of 1

Corporation Cooling Water Exchanger Unit Barbados, W. I. 3 Manufacturer Model * * Frames/Unit 4 Size, Type *-* 5 Surface/Unit * ft2 Effective
1 Service 2 Location 6 P&ID No. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Fluid Allocation Fluid Circulated Total Fluid Entering Vapor (In/Out) Liquid Steam Non-Condensables Fluid Vaporized or Condensed Steam Condensed Temperature Density, Specific Gravity Viscosity Vapor Molecular Weight Specific Heat Thermal Conductivity Latent Heat Operating Pressure, Inlet Velocity Min. X Max. Pressure Drop, Clean (Allow./Calc.) Fouling Resistance 3,097,238 Heat Exchanged Transfer Rate, Service Allocation Design Pressure psig Test Pressure psig Design Temperature F Number of Passes per Frame Corrosion Allowance in. Connections Size & Rating Plot Plan No. PERFORMANCE OF ONE UNIT HOT SIDE lb/h lb/h lb/h lb/h lb/h lb/h lb/h F cP Btu/lbF Btu/hftF Btu/lb psig fps psi

Project No.
Equipment No.

1234567

Sandy Forbes
Mfr Ref. No.

P.O. No.

*
Single

No. Req'd ft2

One

One

Connected in

Surface/Frame

*
Other Ref. Dwg No.

Gross

COLD SIDE Cooling Water

31,500 ---31,500 ------------235 0.907 0.54 ---0.867 0.178 ---75 8.0 10 * 10 ---31,500 ------------120 0.929 13.7 ---0.843 0.160 ---206,483 ------------90 0.995 0.76 ---1.0 0.358

206,483 ---206,483 ------------105 0.992 0.65 ---1.0 0.365 ---60 8.0 * *

Btu/ft2hF F

0.001 0.003 ft2hF/Btu Btu/h Log MTD (Uncorrected) 157.0 F Log MTD (Corrected) Transfer Rate, Clean * * Btu/ft2hF CONSTRUCTION AND MATERIALS HOT SIDE COLD SIDE Sketch (Frame, Nozzle Orientation) 125 Code 300 * None 6" 125# FF 6" 125# FF ----

In Out Intermediate lb/fts rv2, Inlet/Outlet Impingement Protection? Yes No. of Plates Frame Capacity (Max. No. of Plates) PART THK, in. C.A., in. MATERIAL Plates Stnless Steel 16 BWG min. 0.03125 Plate Gaskets Carbon Steel * 0.03125 End Cover Carbon Steel * 0.03125

150 Code 300 Two 0.0625 3" 150# RF 3" 150# RF ----

PART Connections Frame Carrying Bar

MATERIAL

THK, in.

C.A., in.

Carbon Steel

0.03125

Stnless Steel Carbon Steel Carbon Steel Carbon Steel

0.03125 0.03125 0.03125 0.03125

Heat Conservation

Stress Relieved (Mark "SR') and/or Radiographed (Mark 'XR') Parts OSHA Type Protective Shroud? Yes Material: Carbon Steel Insulation: Cleaning: Painting: Code Requirements: Stamp? ASME Sec. VIII, Para. 1 (1992) Yes Client Spec.: Weights: Empty Frame * Remarks 1. Items marked with an asterisk (*) to be completed by Vendor.

lb Filled with Water

lb

Rev 0

Date Description 9-Dec-96 For Inquiry

By ABC

Chk. DEF

Appr. XYZ

Rev

Date

Description

By

Chk.

Appr.

Rev. No.

Montemayor

PLATE & FRAME HEAT EXCHANGER SPECIFICATION (English Units)

Sheet

1 of 1

Art Montemayor

Overall Heat Transfer Coefficient

Typical Overall Heat Transfer Coefficients Source: http://www.the-engineering-page.com/forms/he/typU.html Shell and Tube Heat Exchangers Hot Fluid Cold Fluid Heat Exchangers Water Water Organic solvents Organic Solvents Light oils Light oils Heavy oils Heavy oils Reduced crude Flashed crude Regenerated DEA Fouled DEA Gases (p = atm) Gases (p = atm) Gases (p = 200 bar) Gases (p = 200 bar) Coolers Organic solvents Light oils Heavy oils Reduced crude Gases (p = atm) Gases (p = 200 bar) Gases Organic solvents Water Gases Heaters Steam Steam Steam Steam Steam Heat Transfer (hot) Oil Heat Transfer (hot) Oil Flue gases Flue gases Condensers Aqueous vapors Organic vapors Refinery hydrocarbons Vapors with some non condensables Vacuum condensers Water Water Water Water Water
Page 30 of 46

October 02, 2003 Rev: 0

Overall U W/m2-C 800 1,500 100 - 300 100 - 400 50 - 300 35 - 150 450 - 650 5 - 35 100 - 300 Btu/hr-ft2-oF 140 - 264 17 52 17 70 9 53 6 26 79 114 1.0 6 17 53 44 132 62 - 123 11 - 53 13 35 1.0 6 26 70 4 53 26 88 106 211 3 - 44

Water Water Water Water Water Water Water Brine Brine Brine

250 - 750 350 - 700 60 - 300 75 - 200 5 - 35 150 - 400 20 - 300 150 - 500 600 1,200 15 - 250 1,500 4,000 500 1,000 300 - 900 60 - 450 30 - 300 50 - 300 20 - 200 30 - 100 30 -100 1,000 1,500 700 1,000 400 - 550 500 - 700 200 - 500

Water Organic solvents Light oils Heavy oils Gases Heavy oils Gases Steam Hydrocarbon vapors

264 - 700 88 - 176 53 159 11 79 5 53 9 53 4 - 35 5 - 18 5 - 18 176 264 123 176 70 - 97 88 123 35 88

FileName: 186985106.xls.ms_office WorkSheet: Typical "U"

Art Montemayor

Overall Heat Transfer Coefficient

October 02, 2003 Rev: 0

Vaporizers Steam Steam Steam Heat Transfer (hot) oil Aqueouos solutions Light organics Heavy organics Refinery hydrocarbons 1,000 1,500 900 1,200 600 - 900 250 - 550 176 264 159 211 106 159 44 97

Air Cooled Exchangers Process Fluid (tube side) Water Light organics Heavy organics Gases Condensing hydrocarbons Immersed coils Coil Fluid Pool Fluid Natural circulation Steam Dilute aqueous solutions Steam Light oils Steam Heavy oils Aqueous solutions Water Light oils Water Agitated Steam Steam Steam Aqueous solutions Light oils Dilute aqueous solutions Light oils Heavy oils Water Water

300 - 450 300 - 700 50 - 150 50 - 300 300 - 600

53 - 79 53 - 123 9 - 26 9 - 53 53 - 106

500 1,000 200 - 300 70 - 150 200 - 500 100 - 150 800 1,500 300 - 500 200 - 400 400 - 700 200 - 300

88 176 35 53 12 26 35 88 18 26 140 264 53 88 35 70 70 - 123 35 - 53

Steam Steam Water Water

Jacketed vessels Jacket Fluid Vessel Fluid Dilute aqueous solutions Light organics Dilute aqueous solutions Light organics

500 - 700 250 - 500 200 - 500 200 - 300

88 - 123 44 - 88 35 - 88 35 - 53

Arts Note: Above Us were originally given in metric units and the conversion to good, old fashioned US engineering units is based on:
1.0 Btu/hr-ft2-oF = 5.678263 Watts/m2-oK

Page 31 of 46

FileName: 186985106.xls.ms_office WorkSheet: Typical "U"

Art Montemayor

June 15, 1996 Rev: 0

Some of this data was taken from Standards of the Tubular Exchanger Manufacturers Association (TEMA); 7th Edition (1988); page 178. Note: some of the Wall Tube flow thickness Tube I. D. area inches inches in2 0.165 0.148 0.134 0.120 0.109 0.095 0.083 0.072 0.065 0.058 0.049 0.035 0.028 1/2" O. D. Condenser tube 3/4" O. D. Condenser tube Surface area per Tube flow Surface area per linear Tube weight Constant Tube I. D. area per linear foot, linear foot, ft2 foot, ft2 ** inches C 2 Outside Inside Outside Inside lb of steel* in

BWG 7 8 9 10 11 12 13 14 15 16 17 18 20 22

0.282 0.334 0.370 0.402 0.430 0.444

0.0625 0.0876 0.1075 0.1269 0.1452 0.1548

0.1309 0.1309 0.1309 0.1309 0.1309 0.1309

0.0738 0.0874 0.0969 0.1052 0.1126 0.1162

0.456 0.370 0.302 0.236 0.174 0.141 168 198 227 241

0.482 0.510 0.532 0.560 0.584 0.606 0.620 0.634 0.652 0.680

0.1825 0.2043 0.2223 0.2463 0.2679 0.2884 0.3019 0.3157 0.3339 0.3632

0.1963 0.1963 0.1963 0.1963 0.1963 0.1963 0.1963 0.1963 0.1963 0.1963

0.1262 0.1335 0.1393 0.1466 0.1529 0.1587 0.1623 0.1660 0.1707 0.1780

NOTES: * The weight of the condenser tubes is based on low carbon steel with a density of 0.2836 lbs/in3. For other metal materials multiply by the following factors Material Aluminum Titanium A.I.S.I. 300 Series Stainless Steels A.I.S.I. 400 Series Stainless Steels Aluminum Bronze Aluminum Brass Nickel-Chrome-Iron Admiralty Nickel Nickel-Copper Copper and Cupro-Nickels Factor 0.35 0.58 0.99 1.02 1.04 1.06 1.07 1.09 1.13 1.12 1.14

** Liquid Velocity within the tubes = (Lbs Per Tube Hour) / (C * Liquid Specific Gravity) in feet per sec. (Specific gravity of Water @ 60 oF = 1.00) Page 32 of 46 FileName: 186985106.xls.ms_office WorkSheet: Condenser Tubes Data

Art Montemayor (1988); page 178. Note: some of the tabular TEMA data contained ERRATA, but this was corrected with this spreadsheet's formulas.

June 15, 1996 Rev: 0

Condenser tube 1" O. D. Condenser tube 1-1/4" O. D. Condenser tube Surface area per Surface area per Tube flow Tube flow Tube weight Tube weight Constant Tube I. D. Constant Tube I. D. 2 area area per linear foot, per linear foot, linear foot, ft linear foot, ft2 ** inches inches C ** C 2 2 Outside Inside Outside Inside lb of steel lb of steel in in 0.890 0.6221 0.3272 0.2330 0.670 0.3526 0.2618 0.1754 1.473 550 0.920 0.6648 0.3272 0.2409 0.704 0.3893 0.2618 0.1843 1.348 0.954 0.7148 0.3272 0.2498 0.883 285 0.732 0.4208 0.2618 0.1916 1.241 656 0.982 0.7574 0.3272 0.2571 0.808 319 0.760 0.4536 0.2618 0.1990 1.129 708 1.010 0.8012 0.3272 0.2644 0.747 347 0.782 0.4803 0.2618 0.2047 1.038 749 1.030 0.8332 0.3272 0.2697 0.665 384 0.810 0.5153 0.2618 0.2121 0.919 804 1.060 0.8825 0.3272 0.2775 0.592 418 0.834 0.5463 0.2618 0.2183 0.814 852 1.080 0.9161 0.3272 0.2827 0.522 450 0.856 0.5755 0.2618 0.2241 0.714 898 1.110 0.9677 0.3272 0.2906 0.476 471 0.870 0.5945 0.2618 0.2278 0.650 927 1.120 0.9852 0.3272 0.2932 0.429 492 0.884 0.6138 0.2618 0.2314 0.584 1.130 1.0029 0.3272 0.2958 0.367 521 0.902 0.6390 0.2618 0.2361 0.498 997 1.150 1.0387 0.3272 0.3011 0.268 567 0.930 0.6793 0.2618 0.2435 0.361 1,060 1.180 1.0936 0.3272 0.3089

terials multiply by the following factors:

ty of Water @ 60 oF = 1.00) Page 33 of 46 FileName: 186985106.xls.ms_office WorkSheet: Condenser Tubes Data

Art Montemayor

June 15, 1996 Rev: 0

Condenser tube 1-1/2" O. D. Condenser tube 2" O. D. Condenser tube Surface area per Surface area per Tube flow Tube flow Tube weight Tube weight Constant Tube I. D. Constant Tube I. D. 2 area area per linear foot, per linear foot, linear foot, ft linear foot, ft3 ** inches inches C ** C 2 3 Outside Inside Outside Inside lb of steel lb of steel in in 2.059 970 1.914 1,037 1.170 1.0751 0.3927 0.3063 2.355 1.744 1.200 1.1310 0.3927 0.3142 2.165 1.599 1,182 1.230 1.1882 0.3927 0.3220 1.970 1,860 1.450 1,250 1.260 1.2469 0.3927 0.3299 1.771 1.760 2.4328 0.5236 0.4608 1.341 1,305 1.280 1.2868 0.3927 0.3351 1.635 2,014 1.782 2.4941 0.5236 0.4665 1.173 1,377 1.310 1.3478 0.3927 0.3430 1.427 1.810 2.5730 0.5236 0.4739 1.059 1,440 1.330 1.3893 0.3927 0.3482 1.286 2,180 1.834 2.6417 0.5236 0.4801 0.883 1.360 1.4527 0.3927 0.3560 1.070 0.824 1,537 1.370 1.4741 0.3927 0.3587 0.997 2,300 0.763 1.380 1.4957 0.3927 0.3613 0.924 0.641 1,626 1.400 1.5394 0.3927 0.3665 0.775 0.455 1,706

Page 34 of 46

FileName: 186985106.xls.ms_office WorkSheet: Condenser Tubes Data

Art Montemayor

June 15, 1996 Rev: 0

ndenser tube Tube Constant weight per C ** linear foot,

2.412 2.204 1.935 1.701

3,795 3,891 4,014 4,121

Page 35 of 46

FileName: 186985106.xls.ms_office WorkSheet: Condenser Tubes Data

Heat Exchanger Tubesheets Art Montemayor From: Chemical Engineering Magazine; Plant Notebook; May 12, 1975 Tubesheet Thickness

October 09, 1991 Rev: 0

The thickness of heat exchanger tubesheets is an important consideration in cost-estimating and selecting design alternatives for process heat systems. According to the Tubular Exchanger Manufactureres Assn. (TEMA) standards, the tubesheet thickness for shell-and-tube exchangers is given by the formula:

FG T 2

P S

F G P S T

= = = = =

1.25 12 350 17,500 1.06

inches psig psi inches

TEMA gives precise rules for determining the variables F, G, P, and S for exchanger design. For estimating purposes, however, these terms can be taken as: T = Tubesheet thickness, inches F = a factor = 1.0 for stationary and floating-head tubesheets = 1.25 for U-tube tubesheets G = shell internal diameter, as calculated from transfer surface and tube dimensions, inches P = design pressure, psig S = tubesheets' material allowable stress, psi Values of S for some common materials are shown in the following table. With this table and the other terms, tubesheet thickness can be calculated in this spreadsheet. Material SA-516 Grade 70 Stainless Steel 1.25Cr - 0.5Mo - Si Steel Monel SB-171 Naval Brass SB-402 Copper Nickel SB-11 Copper Temperature, oF 200 300 400 17,500 17,500 17,500 17,700 16,100 15,900 15,000 15,000 15,000 16,500 15,500 14,800 12,500 10,500 2,000 10,500 10,400 10,400 5,700 5,000 --

100 17,500 -15,000 17,500 -12,500 6,600

500 17,500 -15,000 14,700 -10,400 --

Page 36 of 46

FileName: 186985106.xls.ms_office WorkSheet: TubeSheet

Art Montemayor

Tubesheet Layout SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS (TUBE COUNTS) Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (1950); page 841

November 11, 1997 Rev: 0

3/4" O. D. tubes on 1-inch square pitch Shell I. D. Inches 8 10 12 13-1/4 15-1/4 17-1/4 19-1/4 21-1/4 23-1/4 25 27 29 31 33 35 37 39

1" O. D. tubes on 1-1/4 inch square pitch

1-1/4" O. D. tubes on 1-9/16 inch square pit

1 2 4 6 8 1 2 4 6 8 1 2 4 TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass 32 52 81 97 137 177 224 277 341 413 481 553 657 749 845 934 1049 26 52 76 90 124 166 220 270 324 394 460 526 640 718 824 914 1024 20 40 68 82 116 158 204 246 308 370 432 480 600 688 780 886 982 20 36 68 76 108 150 192 240 302 356 420 468 580 676 766 866 968 21 32 48 61 81 112 138 177 213 260 300 341 406 465 522 596 665 16 32 45 56 76 112 132 166 208 252 288 326 398 460 518 574 644 14 26 40 52 68 96 128 158 192 238 278 300 380 432 488 562 624 24 38 48 68 90 122 152 184 226 268 294 368 420 484 544 612 16 30 32 44 56 78 96 127 140 166 193 226 258 293 334 370 12 24 30 40 53 73 90 112 135 160 188 220 252 287 322 362 10 22 30 37 51 71 86 106 127 151 178 209 244 275 311 348

60 70 108 142 188 234 292 346 408 456 560 648 748 838 948

36 44 64 82 116 148 184 222 260 286 358 414 472 532 600

Note: These tube counts can be taken only as an estimate. For accurate tube counts, an actual scaled layout should be done. Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type, orientation, and Outer Tube Limits (OTL) this data Consequently, the user is advised to scrutinize this information before using it. Another estimating method for tube counts is found in "Petroleum Refinery Engineering"; Nelson; McGraw-Hill; Page 544: The number of heat exchanger tubes can be estimated from the equation

N = C * (L/P)2
where, C = 0.75 (a constant for Square pitch) P = the tube spacing, in inches L = the Outer Tube Limit, in inches The OTL is about 1-1/2" less than the inside diameter of the shell in floating head exchangers. Page 37 of 46 FileName: 186985106.xls.ms_office WorkSheet: Square Pitch

Art Montemayor

Tubesheet Layout

November 11, 1997 Rev: 0

It is about 5/8" less than the shell inside diameter of fixed-head or U-tube construction. Tube Spacing = Outer Tube Limit = 1.5 inches 13.5 inches Number of Tubes = 61

Page 38 of 46

FileName: 186985106.xls.ms_office WorkSheet: Square Pitch

Art Montemayor

Tubesheet Layout

November 11, 1997 Rev: 0

9/16 inch square pitch

1-1/2" O. D. tubes on 1-7/8 inch square pitch

6 8 1 2 4 6 8 TubePass TubePass TubePass TubePass TubePass TubePass TubePass

16 22 35 48 64 82 102 123 146 174 202 238 268 304 342

16 22 31 44 56 78 96 115 140 166 193 226 258 293 336

16 22 29 39 50 62 78 94 112 131 151 176 202 224 252

16 22 29 39 48 60 74 90 108 127 146 170 196 220 246

12 16 25 34 45 57 70 86 102 120 141 164 188 217 267

12 16 24 32 43 54 66 84 98 116 138 160 182 210 230

22 29 39 50 62 78 94 112 131 151 176 202 224

imits (OTL) this data applies.

Page 39 of 46

FileName: 186985106.xls.ms_office WorkSheet: Square Pitch

Art Montemayor

November 11, 1997 Tubesheet Layout SHELL AND TUBE HEAT EXCHANGER TUBESHEET LAYOUTS Rev: 0 (TUBE CO Source: "Process Heat Transfer"; Donald Q. Kern, McGraw-Hill Book Co. (1950) 3/4" O. D. tubes on 15/16-inch triangular pitch 3/4" O. D. tubes on 1-inch triangular pitch

Shell I. D. Inches 8 10 12 13-1/4 15-1/4 17-1/4 19-1/4 21-1/4 23-1/4 25 27 29 31 33 35 37 39

1 2 4 6 8 1 2 4 6 TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass 36 62 109 127 170 239 301 361 442 532 637 721 847 974 1102 1240 1377 32 56 98 114 160 224 282 342 420 506 602 692 822 938 1068 1200 1330 26 47 86 96 140 194 252 314 386 468 550 640 766 878 1004 1144 1258 24 42 82 90 136 188 244 306 378 446 536 620 722 852 988 1104 1248 18 36 78 86 128 178 234 290 364 434 524 594 720 826 958 1072 1212 37 61 92 109 151 203 262 316 384 470 559 630 745 856 970 1074 1206 30 52 82 106 138 196 250 302 376 452 534 604 728 830 938 1044 1176 24 40 76 86 122 178 226 278 352 422 488 556 678 774 882 1012 1128 24 36 74 82 118 172 216 272 342 394 474 538 666 760 864 986 1100

Note: These tube counts can be taken only as an estimate. For accurate tube counts, an actual scaled layout should be d Kern does not reveal where he obtained this information and he is not specific in giving details to what TEMA type, o As an example of a discrepancy, refer to the 8" shell with 3/4" tubes on 15/16" triangular pitch and 2-passes. An ac Consequently, the user is advised to scrutinize this information before using it. Triangular pitch should never be used with a dirty or fouling fluid on the shellside of an exchanger. This configuratio

Another estimating method for tube counts is found in "Petroleum Refinery Engineering"; Nelson; McGraw-Hill; Pag The number of heat exchanger tubes can be estimated from the equation

N = C * (L/P)2
where, C = 0.86 (a constant for Triangular pitch) P = the tube spacing, in inches L = the Outer Tube Limit, in inches The OTL is about 1-1/2" less than the inside diameter of the shell in floating head exchangers. It is about 5/8" less than the shell inside diameter of fixed-head or U-tube construction. Tube Spacing = Outer Tube Limit = 1.5 inches 17.5 inches Number of Tubes = 117

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Art Montemayor ET LAYOUTS (TUBE COUNTS) raw-Hill Book Co. (1950); page 842

Tubesheet Layout

November 11, 1997 Rev: 0

h triangular pitch

1" O. D. tubes on 1-1/4 inch triangular pitch

1-1/4" O. D. tubes on 1-9/16 inch triangular pitch

8 1 2 4 6 8 1 2 4 6 TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass TubePass 21 32 55 68 91 131 163 199 241 294 349 397 472 538 608 674 766 16 32 52 66 86 118 152 188 232 282 334 376 454 522 592 664 736 16 26 48 58 80 106 140 170 212 256 302 338 430 486 562 632 700 14 24 46 54 74 104 136 164 212 252 296 334 424 470 546 614 688 20 32 38 54 69 95 117 140 170 202 235 275 315 357 407 449 18 30 36 51 66 91 112 136 164 196 228 270 305 348 390 436 14 26 32 45 62 86 105 130 155 185 217 255 297 335 380 425

70 74 110 166 210 260 328 382 464 508 640 732 848 870 1078

4 50 72 94 128 160 202 242 286 316 400 454 532 598 672

22 28 42 58 78 101 123 150 179 212 245 288 327 374 419

scaled layout should be done. ails to what TEMA type, orientation, and Outer Tube Limits (OTL) this data applies. tch and 2-passes. An actual layout yields 48 tubes with 3/16" OTL, as compared with the listed 32 tubes.

hanger. This configuration is impossible to clean mechanically.

Nelson; McGraw-Hill; Page 544:

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Art Montemayor

Tubesheet Layout

November 11, 1997 Rev: 0

inch triangular pitch

1-1/2" O. D. tubes on 1-7/8 inch triangular pitch

8 1 2 4 6 8 TubePass TubePass TubePass TubePass TubePass TubePass

20 26 38 54 69 95 117 140 170 202 235 275 315 357 407

18 27 36 48 61 76 95 115 136 160 184 215 246 275 307

14 22 34 44 58 72 91 110 131 154 177 206 238 268 299

14 18 32 42 55 70 86 105 125 147 172 200 230 260 290

12 16 30 38 51 66 80 98 118 141 165 190 220 252 284

12 14 27 36 48 61 76 95 115 136 160 184 215 246 275

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FileName: 186985106.xls.ms_office WorkSheet: Triangular Pitch

Art Montemayor

Exchanger Shell Size

November 03, 1997 Rev: 0

TOTAL NUMBER OF TUBES IN AN EXCHANGER, Nt:

If not known by direct count, find in the tube count table, Table III, as a function of D otl, the tube pitch, p, and the layout. The shell diameter Di and outer tube limit Dotl given in the table are those for a conventional split-ring floating head design, fully tubed out. For a given shell diameter, the value of Dotl will be greater than that shown for a fixed tube sheet design and smaller for a pull-through floating head. In any case, the tube count can be reasonably interpolated from the Table using the known or specified Dotl, asuming that the tube count is proportional to (Dotl)2. All tube count tables are only approximate since the actual number of tubes that can be fitted into a given tubesheet depends upon the pass partition pattern, the thickness of the pass dividers and exactly where the drilling pattern is started relative to the dividers and the outer tube limit. Additional tubes will be lost from the bundle for a U-tube design because the minimum bending radius prevents tubes from being inserted in some, or all, of the possible drilling positions near the centerline of the U-tube pattern. Tubes will also be lost if an impingement plate is inserted underneath the nozzle. For a no-tubes-in-the-window design, the actual number of tubes in the bundle is FcNt. Fc is the fraction of total tubes in crossflow.

Outer Tube Tube OD Tube Limit in Pitch, in. Diameter, in. 0.75 0.9375 0.75 1.0000 8.071 6.82 0.75 1.0000 (Sch. 30) 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 10.02 8.77 0.75 1.0000 (Sch. 40) 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 12.00 10.75 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 13.25 12.00 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 15.25 14.00 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 17.25 16.00 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 19.25 18.00 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 21.00 19.25 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 23.25 21.50 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 25.00 23.25 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 27.00 25.25 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 29.00 27.25 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 31.00 29.25 0.75 1.0000 1.00 1.2500 1.00 1.2500 0.75 0.9375 0.75 1.0000 33.00 31.25 0.75 1.0000 1.00 1.2500 Shell ID in.

Tube Layout Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square

Number of Tube Passes 1 38 32 37 21 22 62 52 61 32 37 109 80 90 48 57 127 95 110 60 67 170 138 163 88 96 239 188 211 112 130 301 236 273 148 172 361 276 318 170 199 2 32 26 30 16 18 56 52 52 32 32 98 72 84 44 52 114 90 101 56 63 160 132 152 82 92 224 178 201 110 124 282 224 256 142 162 342 264 308 168 188 4 26 20 24 16 16 47 40 48 26 28 86 68 72 40 44 96 81 90 51 56 140 116 136 75 86 194 168 181 102 116 252 216 242 136 152 314 246 279 157 170 6 24 20 24 14 14 42 36 48 24 28 82 68 70 38 42 90 77 88 46 54 136 112 133 70 84 188 164 176 98 110 244 208 236 129 148 306 240 269 150 164 8 18

36

60 68 36 40 86 70 74 44 50 128 108 110 64 72 178 142 166 82 94 234 188 210 116 128 290 234 260 148 160

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33.00 Art Montemayor31.25 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 0.75 0.75 0.75 1.00 1.00 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 0.9375 1.0000 1.0000 1.2500 1.2500 Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang. Triang. Square Triang. Square Triang.

Exchanger Shell Size

November 03, 1997 Rev: 0

35.00

33.25

37.00

35.25

39.00

37.25

42.00

40.25

44.00

42.25

48.00

46.00

52.00

50.00

56.00

54.00

60.00

58.00

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Art Montemayor

Tube Layouts

November 03, 1997 Rev: 0

TUBE PITCH PARALLEL TO FLOW, PP, AND NORMAL TO FLOW, PN These quantities are needed only for the purpose of estimating other parameters. If a detailed drawing of the exchanger is available, or if the exchanger itself can be conveniently examined, it is better to obtain these other parameters by direct count or calculation. The quantities are described by Figure 5.2-1 and read from Table IV for the most common tube layouts.

Tube OD, in.

Tube Pitch, in.

Layout

Pp, in.

Pn, in.

0.625 0.750 0.750 0.750 0.750 1.000 1.000 1.000

0.8125 0.9375 1.0000 1.0000 1.0000 1.2500 1.2500 1.2500

0.704 0.814 1.000 0.707 0.866 1.250 0.884 1.082

0.406 0.469 1.000 0.707 0.500 1.250 0.884 0.625

Art Montemayor

Heat Exchanger Tube Layouts

March 12, 1997 Rev: 0

Flow

30o Triangular

60o Rotated Triangular

Note: Flow arrows are perpendicular to the baffle cut edge

Flow

Rotated Square

Square

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FileName: 186985106.xls.ms_office WorkSheet: Tube Pitch Types