3.

Design and Operation

 Illustrate, label and describe the parts of the heat exchanger (assigned topic).
 Its physical and thermal design parameters should be added here as well such as the
required size, shape, and structure, temperature range during operation, required mass
flow rate, pressure drop on the tube side, etc.

Tubes
The majority of shell and tube heat exchangers are made of tubes. They act as a heat
transfer surface between a fluid moving within the tube and a fluid flowing around the outside of
the tube. The tubes' exteriors can be left naked or have expanded or enhanced (finned) surfaces.
Larger-diameter tubes are used for mechanical cleaning or to lessen pressure drop on occasion.

Tubesheets
The tube sheet is a single circular metal plate that has been drilled and grooved to take
the tubes, gaskets, spacer rods, and the bolt circle that secures it to the shell. The tube pitch,
which is normally 1.25 times the outside diameter of the tubes, is the distance between the center
of the tube holes. Other tube pitches are routinely used to reduce shell side pressure loss and
control fluid velocity as it passes through the tube bundle. Tubes can be welded to the front or
back face of a tube sheet. The term "strength welding" refers to a welding procedure that is
mostly responsible for the mechanical strength of the connection. Seal welded joints are required
when employing clad tube sheets, tubes with a wall thickness of less than 16 BWG (0.065
inches), and some metals that cannot be suitably expanded to provide a good mechanical
connection.
Shell and Shell-Side Nozzles
The nozzles serve as the entrance and departure points, while the shell serves as a
container for the shell-side fluid. The roundness of the shell determines the maximum diameter
of the baffles that can be inserted as well as the effect of shell-to-baffle leakage. An impingement
plate is typically utilized on the nozzle to prevent the incoming fluid jet from crashing into the
top row of tubes at high velocity.

Tube-Side Channel and Nozzles

The flow of fluid into and out of the heat exchanger's tubes is controlled using channels
and nozzles. Channel covers are circular plates that mount to the channel flanges and may be
removed for tube inspection without causing any damage to the tube side pipework. Bonnets
with flanged nozzles or threaded connections for tube-side piping are frequently used in place of
channels and channel coverings in smaller heat exchangers.

Pass Dividers
A pass divider is required in one channel or bonnet of an exchanger with two tube-side
passes, and it is required in both channels and bonnets of an exchanger with more than two
passes. If the channels or bonnets are cast, the dividers are integrally cast and then faced to give a
smooth bearing surface on the gasket between the divider and the tube sheet.

Baffles
The cross-flow velocity, and hence the rate of heat transfer and pressure decrease, are
determined by the baffle pitch and baffle cut. Segmental cuts with a segment height of around
25% of the shell diameter are usually the best. Baffle cuts that are too large or too little result in
poorly distributed shell-side flow, massive eddies, dead zones behind the baffles, and significant
pressure drops. For many high-velocity gas flows, the single segmental baffle layout results in an
unacceptable high shell side pressure loss. Pressure drop can be minimized by a factor of four
when using double or triple segmental arrangements. Longitudinal baffles are occasionally
employed to split the shell, resulting in many shell channels. This type of heat exchanger can be
useful in heat recovery applications on occasion.

Tie Rods
The baffle assembly is held together with tie rods and spacers, and the baffle spacing is
maintained with spacers. The tie rods are fastened to the tube sheet on one end and the final
baffle on the other. They are responsible for keeping the baffle assembly together. The spacers
are put over the tie rods between each baffle to maintain the selected baffle pitch. The minimal
number of tie rods and spacers necessary is determined by the size of the tie rods and spacers, as
well as the diameter of the shell.