ADAMSON UNIVERSITY

COLLEGE OF ENGINEERING
CHEMICAL ENGINEERING DEPARTMENT

MODULE 8: SUMMATIVE ASSESSMENT

NAME: Palma, Allan Arnold V.

YEAR / SECTION:5th/51137

INSTRUCTIONS: FILL IN THE BLANKS OR ENCIRCLE THE WORD(S) THAT WILL SATISFY THE
STATEMENT.

INTRODUCTION
1) A simple heat exchanger is a set of steel tubes enclosed in a tank.

The tank represents the shell of the exchanger and, in this case, is filled with water .
2) Heat is transferred from the hot oil flowing through the tubes to the cool water around the tubes.
The conductor of the heat is the tube wall.
3) The shell-side of an exchanger is the area inside the shell and outside the tubes.
The tube-side of an exchanger is the area inside the tubes.
4) In the example shown, the shell-side fluid is water and the tube-side fluid is hot oil .
5) This drawing shows the construction of a typical shell and tube exchanger.

The tubes are anchored between two tube sheets .

6) The combination of tubes and tubesheets is called the tube bundle .
7) This drawing shows the fluid flow path through a shell and tube exchanger.
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ASSESSMENT

Hot oil flows into the tube-side inlet, through the tubes, and out through the tube side
outlet,
8) Cool water flows into the shell-side inlet, around the tubes , and out through the
shell- side outlet.
9) In this example, heat is transferred from the (tube side / shell side) fluid to the shell side
fluid.

TUBE BUNDLE
10) The greater the surface area of a conductor, the (more / less) quickly heat is conducted.
11) A bundle of small tubes has (more / less) surface area than a single large tube.
12) Shell and tube exchangers use a bundle of small tubes, rather than a single large tube. This
(increases / decreases) the area for heat transfer.
13) Exchanger tubes can be either plain or finned.

inscribing circumscribing
As these drawings show, fins are eith the tubes.
er or
14) Fins (add to / subtract from) the tube surface area.
15) Thus, they inscribing the rate of heat transfer.
16) If a corrosive fluid passes through either side of an exchanger, something usually must be done
to prevent corrosion .
17) If a corrosive fluid passes through either side of an exchanger, something usually must be done
to prevent corrosion .
18) Sometimes the tubes can be made of a metal which is not easily corroded .

Refer to Exhibit 1 for Numbers 19 – 21.

19) The outside diameter (O.D.) ranges from 1/4 – inch to 1/2 – inches.
20) In practice, the most common tube O.D.’s are 1/2 – inch, the 3/4 – inch, and the one-inch. As the
chart shows, tubes with O.D.’s at the extremes of the range, either high or low, are usually
produced in (greater / fewer) varieties of gauges than the more common sizes.
21) So, tubing with a 2-1/2 inch O.D. is usually produced in only one gauge .
22) Exchangers are usually produced in standard lengths of 8, 10, 12, 16, and 20 feet. Sixteen and 20
feet are the most common lengths. The particular application usually determines the length of
an exchanger.
23) That is, exchanger design is determined by cost and the particular operating conditions .
24) As the length of an exchanger increases, its cost generally (increases / decreases).
25) One of the basic considerations in exchanger design is to meet operating requirements
while minimizing cost .

TUBESHEETS
26) The tube bundle is made by fastening the tube ends into the openings in the tubesheet.
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Because the tubes cannot move in the tubesheets, the tubesheets and tubes form a (solid / flexible)
unit.
27) In some exchangers, the tube and tubesheets are fixed to the shell. Therefore, they (are free to
move / are prevented from moving).
28) Heat causes metal to (expand / contract).
29) When the tubes expand because of heat, stress is placed on the tubes and tubesheet.

A tube can come loose, allowing fluid to leak between the tube wall and the opening in the
tube sheet .
30) This results in the contamination of one fluid by another. To guard against this, a double
tubesheet can be used in cases where a leak absolutely cannot be tolerated.
31) Here is a design which can help reduce the possibility of leaks at the tubesheet.
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This design provides for a space between the tubesheets.

32) If a leak occurs, fluid passes into this space. Since the space between the tubesheets is open, fluid
is allowed to (drain from / collect in) the heat exchanger.

TUBE JOINTS
33) The tube joint is the connection between the tube and the tubesheet. The better the fit at the tube
joint, the smaller the possibility that there is leakage.
34) Tube joints are usually either rolled press fit or welded.

Some metals cannot be welded, so tubes of these metals are rolled press fitted.
35) Rolled joints usually make a very good seal, and they can be used in reasonably high pressure
service, up to about 2,000 psi. However, in special cases or severe service, welded tube
joints are usually used.
36) An exchanger is likely to be more expensive if the tube joints are (rolled /welded).

TUBESHEET LAYOUT
37) Exchanger tubes can be installed in a variety of patterns.
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38) When the tubes are arranged in parallel rows, vertically and horizontally, the pitch is
called
least pitch.
39) In-line square pitch offers the (most / least) resistance to shell-side flow through an exchanger.
40) The greater the resistance to flow, the greater the resulting pressure drop. For this reason, in-
line square pitch is particularly efficient when conditions require a (high / low) pressure drop.
41) Staggering the tubes, as in the three other main types of pitch, allows (more / fewer) tube in a
given area than the even spacing in square pitch does.
42) A disadvantage of square pitch is the relatively less number of tubes in a given area.
43) Compare the number of tubes in a given area in square pitch and triangularpitch.

In a 42-inch, double pass exchanger, there are 1176 tubes in a square pitch arrangement and
1350 tubes in a triangular pitch arrangement.
44) The more tubes there are in a givenarea, the greater the heat transfer rate.
45) Since the square pitch arrangement results in the lowest number of tubes in a given area, it also
results in lowest heat transfer rate.
46) When the pitch is triangular, the pressure drop is (higher / lower) than when the pitch issquare.
47) But the heat transfer rate is greater when the pitch is triangular .
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48) For a given set of operating conditions the choice of pitch arrangement depends upon what
pressure drop is needed in relation to the heat transfer rate desired.

BAFFLES AND TYPES OF BAFFLES

49) The longer the tubes in an exchanger are, the (heavier / lighter) theyare.
50) The heavier they are, the greater the chance that they will sag.
51) Baffles support the weight of the tubes.

Since they support the weight, baffles help to decrease the stress on the tubing and tubesheet.
52) In both laminar and turbulent flow, a layer of fluid surrounds each tube, acting as an insulator.
This layer of fluid acts to (increase / decrease) the rate of heat transfer.
53) The thicker the insulating layer, the more it decreases heat transfer.
54) The insulating layer is likely to be thicker when flow is (laminar / turbulent).
55) In addition to supporting the tubes, baffles break up laminars flow, decreasing the layer
of insulating fluid.

SEGMENTAL BAFFLES
56) A segmental baffle is a circle from which either a vertical or horizontal portion has beencut.

In this case the baffles are (vertically cut / horizontally cut) segmental baffles.
57) Segmental baffles are positioned so that the cut-out areas (all face in same direction / face in
alternate directions).
58) Alternating the baffles causes flow to cross the tubes a number of times.
59) It also provides better support for the tubes.
60) In addition to the portion cut from the side or top of a segmental baffle, a portion is often
removed from the bottom.
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Removing this portion (allows / prevents) some continuous fluid flow along the bottom of the
heat exchanger.
61) Whether the baffles cut is vertically or horizontally depends on the type of fluid and on the
operation.

The baffle most likely to catch suspended materials is the (vertical / horizontal) baffle.

62) But, suppose horizontal baffles were used in a condenser.

restricting
Condensed fluid builds up behind baffles A and C, thu low.
s f
63) Drainage from the condenser is prevented and the efficiency of theexchanger is decreased .

DISC AND DOUGHNUT BAFFLES

64) The pattern of flow through disc and doughnut baffles is relatively uniform.
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But, if the fluids are not clean, sediment builds up behind the (disc / doughnut).
65) Since the cutout area of the baffle is in the center, the flow of condensed fluids along the bottom
of the exchanger can also be restricted .

IMPINGEMENT BAFFLES
66) At high inlet-fluid velocities, the fluid can seriously erode the tubes as it strikes them. If the inlet
fluid contains suspended solid particles, the problem is (more / less) severe.
67) Impingement baffles are sometimes placed at inlet flow areas to the shell-side.

As this comparative illustration shows, the impingement baffle helps to (spread out / contain)
fluid flow.

68) An impingement baffle directs the flow (toward the sides of the exchanger / toward the tubes).
69) The baffle effectively reduces the errosion of the tubes.
70) Besides reducing erosion, spreading the fluid insures that the fluid contacts all the tubes. And
increasing fluid-tube contact increases the heat transfer rate.

LONGITUDINAL BAFFLES
71) Longitudinal baffles are sometimes used to split shell-side flow into two or morepasses.
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ASSESSMENT

As the drawing shows, the longitudinal baffle (is somewhat shorter / extends the full length of)
the exchanger.

72) This allows for the return, or double pass, through the exchanger.

Three longitudinal baffles would provide four passes through the exchanger.

73) This drawing illustrates the baffles position for divided flow.

In this case, fluid flow on the two sides of the tubes is (consecutive / simultaneous).
EFFECTIVE HEAT TRANSFER SURFACE
74) The heat transfer surface depends on the number of tubes, on the length of the tubes, on the
length of the tubes, and on the outside diameter of the tubes. As any of these increase, the
effective heat transfer surface also increases .
75) The entire length of a tube is not the effective length of the tube, as far as heat transfer goes. Since
the tube extends through the tubesheet at each end of the exchanger, the effective length
is
shorter than the actual length.
76) For 15-foot tubes extending three inches through a tube-sheet at each end, the effective length is
about 4-1/2 feet.
77) The formula for calculating the effective tube surface in an exchanger is:
Effective surface = (square foot external surface per foot length) x (net effective tube length) x
(number of tubes)
If the square foot of external surface per length is 0.2618 and the net effective tube length is 15.5
feet and the number of tubes is 682, then the effective tube surface is 2767.49 .

RefertoExhibit2fornumbers78-85.
SHELL-SIDE FLOW ARRANGEMENTS
78) Shell-side flow arrangements are generally one of the six illustrated in Exhibit 2.
In a one-pass shell, the shell-side fluid enters one end of the exchanger, and exits through (the
same end / different) of the exchanger.
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79) A double pass requires that fluid enters and exits through (the same end / different ends) of the
exchanger.
80) As the exhibit shows, a split flow arrangement divides incoming shell fluid into two
separate streams.
81) A double split flow divides shell fluid into four separate streams.
82) In the divided flow arrangement shown, shell fluid enters at the center of the
exchanger, rather than at the end.
83) The kettle – type reboiler has (split / divided) flow and a dome outlet forvapors
84) The choice of shell arrangement depends on the amount of cooling or heating required, on the
pressure drop that is needed, and on the type of service. For instance, the shell arrangement that
provides space for vapors to accumulate is the kettle - type boiler .
85) The effective “time” that the shell-side fluid is in contact with the tubes increases as the number
of passes increases .
86) The drawing illustrates a single-pass tube arrangement

Tube-side fluid enters one end of the exchanger, flows through all the tubes in the same
direction , and leaves at the opposite end of the exchanger.
87) A tube-side baffle can be built into the head end of the exchanger to direct flow through the tubes.

In a two-pass arrangement, fluid flows through half the tubes in one direction and through half
the tubes in one direction and through the other half of the tubesin the opposite direction.

88) The channel head baffle in a two-pass tube arrangement is positioned (vertically / horizontally).

89) Compare the two-pass arrangement with the four-pass arrangement.

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A four-pass arrangement requires two channel head baffle(s) and one

floating head baffles(s).

90) Increasing the number of passes requires increasing the number of baffles.

TYPES OF SHELL AND TUBE EXCHANGERS

FIXED TUBESHEET EXCHANGERS
91) In the fixed tubesheet type exchanger, the tubesheet is welded to the shell.

The tube bundle (can be removed from the shell / is permanently installed).
92) Expansion and contraction because of temperature changes place stress on the tube bundle. In
this type of exchanger, the tube bundle (can expand to compensate for the stress / is prevented
from expanding).
93) Fixed tubesheet exchangers are used when the temperature range is (limited /wide).
94) The drawing shows an expansion joint built into the shell of a fixed tubesheetexchanger.
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As the tubes become hotter, they (expand / contract).

95) The built-in joint allows the shell to expand also.
96) As the tubes and shell cool, the expansion joint and tubes contract .
97) Stress on welding and on the tubes and shell is decreased .
98) Because of the difficulties of inspecting and cleaning fixed tubesheet exchangers, they are
generally used where shell-side fouling is (limited / extensive).
99) Because the tube bundle cannot be removed from the shell, the shell side of a fixed tubesheet
exchanger must be cleaned (mechanically / chemically).

Refer to Exhibit 3 for numbers 100-109.

U-TUBE OR U-BEND EXCHANGERS
100) Exhibit 3 shows a U-tube exchanger has (only one / two) tubesheet(s).
101) A baffled channel is bolted between the tubesheet and the channel cover .
102) The tubesheet and tube bundle form a unit. By unbolting the channel from the shell,
the tubesheet and tube bundle can be removed from the shell so the (inside / outside) of the
tubes
can be cleaned.
103) However, the bend in the tubes inhibits cleaning andinspecting the inside of the tubes.
104) Since the tube bundle in a U-tube exchanger is fastened to only one tubesheet, the tubes are
(free to expand / prevented from expanding).
105) U-tube exchangers can be used where the temperature difference between shell-side and
tube-side fluids is quite high .
106) Exhibit 3 also shows the flow patterns in a U-tube exchanger. The baffle dividing the channel
directs incoming tube-side fluid through (all / only the upper half) of the tube openings.
107) Tube-side fluid flows through the tubes, around the bend, and through the lower
chamber.
108) Tube-side flow, in this case, is (one-pass / two-pass) flow.
109) Shell-side flow in this exchanger is (one-pass / two-pass) flow.

FLOATING HEAD
EXCHANGERS PULL-THROUGH
TYPE
110) In this exchanger, the tubesheet on the right is bolted between the channel and shell in a
fixed position.
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But, the tubesheet on the left, together with a cover, floats inside the shell, (free to move / unable
to move) horizontally.
111) Because of the weight of the tube bundle, there (is / is no) vertical movement.
112) But, since the tube bundle and floating head can move horizontally, the tubes are free to
expand and contract .
113) After unbolting the channel flange and the stationary tubesheet, the tube bundle and the
floating head can be withdrawn as a unit.

This permits cleaning and inspecting the outside of the tubes.

114) In this illustration, the channel cover, the shell cover, and the floating head cover have
been removed.

This provides access to both tubesheets and to the insides of the tubes.
115) By removing the floating head cover and the channel cover, it is possible to inspect and
clean the inside of the tubes.
116) In a pull-through type floating-head exchanger (all / some) parts of the exchanger can be
inspected and cleaned.
117) This drawing illustrates a disadvantage of the pull-through exchanger.
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ASSESSMENT

The clearance between the shell and the tubes is large.

118) This clearance is provided to accommodate the outside diameter of the floating tubesheet.
Since no tubes can occupy this space, the space is wasted .
119) In addition, fluid is likely to move through the space rather than pastthe tube bundles .
120) For these reasons, the clearance space between the shell and tube bundle reduces the
effectiveness of the pull-through exchanger.

SPLIT BACKING-RING TYPE

121) A second floating head exchanger is the split backing-ring type.

Notice that the diameter ofthe shell cover is greater than the diameter of the rest of the shell
holding the tubes.
122) The tubes and tubesheet and floating head cover (can be pulled / cannot be pulled) through
the channel as a unit.

Refer to Exhibit 4 for numbers 123-135.

123) Compare the split backing-ring exchanger and the pull-through exchanger. An advantage of
pull-through exchanger is that the bundle and head can be pulled through the channel as one
unit.
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124) In order to pull the tube bundle of the split ring type, the floating head cover, shell cover,
and split ring must be removed first.
125) However, clearance between the tube bundle and shell is smaller in the (split backing-ring /
pull-through) exchanger.
126) If the same amount of space is available, more tubes can be used in the (split backing-ring /
pull through) exchanger.
127) Therefore, the split backing-ring exchanger is more efficient than pull-through
exchangers.
128) But, the (split backing-ring / pull through) exchanger has more parts.
129) Thus, it is more expensive to build.
130) The split backing-ring exchanger is also (easier / harder) to disassemble.
131) First, the shell cover is unbolted from the shell .
132) Then, the floating head cover and split backing-ring are unbolted from the floating
tubesheet .
133) Then, the channel is unbolted from the other end of the shell .
134) And finally, the tube bundle is pulled from the channel end.
135) Since disassembly is more time-consuming, it is also more costly .

SIZE NUMBERING AND TYPE DESIGNATION

136) Exchanger size, as specified by the Tubular Exchanger Manufacturer’s Association (T.E.M.A.),
depends on the diameter of the shell and length of the tubes in inches. Since shell diameter
is specified first, a size 23-192 exchanger has a diameter of 23 inches and tube 192
inches long.
137) When the shell diameter is between two numbers, such as 33 1/4 inches, it is rounded off to
the nearest whole numbers. An exchanger with 33 1/4 inch diameter and 188 inch long tubes
would be designated size 33-188 .

Refer to Exhibit 2 again for numbers 138-147.

138) As the exhibit shows, type designation includes three variables: the type of stationary
head , the shell type, and the type of rear head.
139) Designations are specified by letters of the alphabet. The four designations of stationary head
types are indicated by the letters A , B , C , and E .
140) Special high pressure stationary head closures are indicated bythe letter D .
141) Shell types are indicated by the letters E, F , G , H , J , and K .
142) Any exchanger including the letter K in its designation is a kettle-type .
143) Rear head types are specified with the letters L , M , N , P , S , T , and U .
144) An example of a complete exchanger designation is size 17-192 type AES. This exchanger has
a 17-inch diameter and 192 -inch long tubes.
145) According to the exhibit, this exchanger has a (removable channel and cover / integral cover)
146) It has a (one-pass / two-pass / split flow) shell.
147) And it has a (fixed tubesheet / U-tube bundle / floating head with backing device).
148) Put the following TEMA exchanger types in the right order of ‘ease of thorough tube-side
cleaning’ (easy to difficult): NEN, AES, BES, BEU
BEU
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BES

NEN

AES

149) Essay: Two AES exchangers in series have trouble heating up a process stream from 50ᵒC to
90ᵒC, and cooling down a hot stream with the same flow rate from 110ᵒC to 70ᵒC.
Luckily, there is an abandoned AES exchanger available that has four times the surface of the two
existing exchangers, and even better, it has the right material and sufficiently high design P & T,
and would fit on the plot space occupied by the existing exchangers. Is replacement a good idea?

150) When heating up a cold stream (5000 kg/h water) from 40ᵒC to 90ᵒC while cooling down a
hot stream (5000 kg/h water) from 110ᵒC to 60ᵒC in AES exchangers, how many shells do you
need?