02a Industrial Plant Cooling Systems – Part 1

ME 426 – Industrial Plant Engineering

Thermofluids Design Part II
1 Heat Exchangers & Cooling Towers
Heat exchanger classifications; Standards of Tubular Exchangers
Manufacturers Association; heat exchanger analysis & calculations;
cooling towers (natural draft and mechanical draft); cooling tower
analysis and calculations

2 Thermal Flow Performance

Evaluation & Design
Heat transfer and pressure drop correlations; temperature flow and
distribution; ancillary rotating equipment

3 Thermal Systems Optimization

Cooling system selection and optimization; cooling system
performance characteristics; cooling water system engineering pitfalls
02-1 Heat Exchangers & Cooling Towers
Heat Exchangers & Cooling Towers

In energy conversion and industrial systems, discharge of heat is necessary.

COMPLEXITIES OF INDUSTRIAL PLANT COOLING SYSTEMS:

1. Adequate plant location and dwindling cooling water supply.

2. Rapidly rising water costs
3. Environmental considerations such as noise restrictions.
4. Existing socioeconomic and political considerations.

COMMON INDUSTRIAL PLANT COOLING SYSTEMS EQUIPMENT:

1. Heat Exchangers (H/X)

2. Cooling Towers
3. Related rotating equipment such as fans and blowers
Heat Exchangers & Cooling Towers

HEAT EXCHANGER (H/X)

• a device that facilitates the process of heat exchange between two fluids
that are at different temperatures
• used in industrial systems, such as refrigeration, heating and air-
conditioning systems, power plants, chemical processing systems, food
processing systems, automobile radiators, and waste heat recovery units
• used in energy conversion; air preheaters, economizers, evaporators,
superheaters, condensers, and cooling towers in a power plant are a few
examples of heat exchangers

CLASSIFICATION OF HEAT EXCHANGERS

A. Based on the nature of the heat exchange process

1. Direct contact–type heat exchanger
2. Regenerator type of heat exchanger
3. Recuperator type of heat exchanger
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CLASSIFICATION OF HEAT EXCHANGERS

B. Based on the direction of fluid flow

1. Parallel flow
2. Counter flow
3. Cross flow

C. Based on the mechanical design

1. Concentric tube heat exchanger
2. Shell and tube heat exchanger
3. Multi-pass heat exchanger

D. Based on the physical state of the working fluid

1. Condenser
2. Evaporator

E. Based on compactness
1. Fin-tube type heat exchanger
2. Plate-fin type heat exchanger
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a) Direct contact-type
b) Regenerator-type
c) Recuperator-type

Figure 1. Based on nature of heat exchange

a) Parallel-flow
b) Counter-flow
c) Cross-flow

Figure 2. Based on fluid flow direction

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Figure 3a. Based on mechanical design

(concentric tube and multi-pass)
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Figure 3b. Based on mechanical design (shell and tube h/x)

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Figure 4. Based on working

fluid physical state (a)
condenser (b) evaporator

Figure 5. Based on
compactness (a) (b) (c) fin-
tube type (d) plate-fin type
Heat Exchangers & Cooling Towers

TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA)

A. TEMA Class

The Tubular Exchanger Manufacturers Association (TEMA) defines the

various types of shell-and-tube exchangers. TEMA defines design and
construction practices. TEMA sets mechanical standards for three
classes of exchangers reflecting the severity of the service. For most
refinery services, offshore, or cold temperatures below 20°F the most
restrictive (more stringent) class is used—TEMA Class R. For other
services (onshore, chemical plants, cold temperatures above 20°F),
TEMA Class C or B exchangers, which are less stringent, are used. In
general, Class R exchangers have thicker shells, larger and thicker
heads, thicker tubes and larger miscellaneous parts.
Heat Exchangers & Cooling Towers

TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA)

B. TEMA Type

Standard terminology to describe components and connections of

shell-and-tube exchangers is provided in Figure 6. The TEMA “Type”
nomenclature consists of three letters describing the stationary head,
shell, and rear head. Common combinations are shown in Figure 7.
Three-letter “Type” description:

• First letter - describes the stationary or front head end

• Second letter describes the shell type (omitted for bundles only)
• Third letter - describes the rear or back head end
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Figure 6. Components of shell-and-tube heat exchangers

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Figure 7. Cut-away view of

shell-and-tube heat exchanger
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TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA)

C. TEMA Classification

TEMA has developed nomenclature for describing shell-and-tube heat

exchangers. It includes a simple code for designating the size and type
of exchanger. In addition, standard terminology has been set up to
specify typical parts and connections. TEMA size is the shell inside
diameter in inches rounded to the nearest integer, followed by the
straight length of the tubes in inches rounded to the nearest integer.
The two dimensions are separated by a hyphen (-). The three-letter
shorthand is shown below.

• First letter - Nominal diameter

• Second letter - Nominal length
• Third letter - Type
Heat Exchangers & Cooling Towers

TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA)

C. TEMA Classification

For kettle reboiler and chillers (that have a narrow end and a fat end),
the nominal diameter is the port (narrow end) followed by the shell
diameter, each rounded off to the nearest integer. The two dimensions
are separated by a slash (/). The tube length for U tubes is taken as the
straight length from end of tube to bend tangent. The “Type” as stated
earlier is defined by a three-letter nomenclature.

- See attached copy of TEMA Standards, 9th edition (2007)

Heat Exchangers & Cooling Towers

TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION (TEMA)

C. TEMA Classification

Example 1: TEMA classification examples

• A fixed tube sheet (L) exchanger with removable channel and cover
(A), single pass shell (E), 23-in. inside diameter with tubes 16 ft long
is denoted TEMA SIZE 23-192 TYPE AEL.
• A pull through floating head (T), kettle type reboiler (K) having
stationary head integral with tube sheet (C), 23-in. port diameter and
37-in. inside shell diameter with tubes 16 ft long is denoted as a
TEMA SIZE 23/37-192 TYPE CKT.
• A 20-foot straight length U-tube bundle (U), 3-foot shell diameter,
with a single shell pass (E) and removable shell cover (A) would be
TEMA SIZE 36-240 TYPE AEU. The same bundle installed in a 5-
foot diameter kettle reboiler (K) would be a TEMA SIZE 36/240
TYPE AKU.
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HEAT EXCHANGER ANALYSIS

The heat transfer analysis of a heat exchanger involves relating the total heat
transfer rate to variables like inlet and outlet temperatures of the hot and cold
fluids, the overall heat transfer coefficient, and the overall heat transfer
surface area. The analysis is essentially based on the energy balance
between the:
• heat gained by the cold fluid
• the heat lost by the hot fluid
• heat transferred through the wall that separates the two fluids

Let mdot , cp, and T denote the mass flow rate, the specific heat, and the
temperature of a fluid, respectively. The subscripts h and c indicate the hot
and cold fluids, respectively. Neglecting the heat transfer between the heat
exchanger and its surroundings (assuming that heat transfer is only between
the hot and cold fluids flowing through the heat exchanger) and neglecting
the changes in kinetic and potential energies of the fluids and assuming a
steady flow, the energy balance for a heat
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Figure 8. Schematic representation of heat exchanger

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Figure 9. Schematic representation for heat exchanger analysis

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For the complete lessons on H/X Calculations, refer to

the attached lecture materials.
Reference Materials:

• Bowman, F., Bowman, S., Engineering of Power Plant and Industrial

Cooling Water Systems (2021). CRC Press Taylor & Francis Group
• Stewart, M. Surface Production Operations, Volume 5: Pressure
Vessels, Heat Exchangers, and Aboveground Storage Tanks:
Design, Construction, Inspection and Testing (2021). Elsevier Inc.
• Balaji, C. et al., Heat Transfer Engineering (2020). Elsevier Inc.
• Kutz, M. Mechanical Engineers Handbook Vol.4 4th ed. Energy &
Power (2014). John Wiley & Sons.
• Tubular Exchange Manufacturers Association (TEMA). Standards of
the Tubular Exchange Manufacturers Association, 9th ed. (2007).
kbcdco.tema.org
• Kroger, D.G. Air-cooled Heat Exchangers and Cooling Towers -
Thermal Flow Performance Evaluation and Design – Volume 1 & 2
(2004). PennWell Corporation
• http://allaboutengineeringworks.blogspot.com/2012/02/lab-report-
heat-exchanger.html
• http://constructionmechanical-
engineering.blogspot.com/2010/03/single-and-multi-pass-heat-
exchanger.html
 Thank You
02a Industrial Plant Cooling Systems - Part 1