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WEBBUSTERZ ENGINEERING SOFTWARE

Shell & Tube Heat

Exchanger DesignHelp File

Version 1.6.0

Khaled Aljundi

Copyright 2011 Khaled Aljundi WeBBusterZ Engineering Software

http://www.webbusterz.comhttp://www.webbusterz.net

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http://www.webbusterz.com

http://www.webbusterz.net 3

Rating Mode .......................................................................................................................................... 35

Step 1 ................................................................................................................................................ 35

Step 2 ................................................................................................................................................ 36

Step 3 ................................................................................................................................................ 37Step 4 ................................................................................................................................................ 38

Step 5 ................................................................................................................................................ 38

Step 6 ................................................................................................................................................ 39

Step 7 ................................................................................................................................................ 40

Step 8 ................................................................................................................................................ 40

Step 9 ................................................................................................................................................ 41

Summary ........................................................................................................................................... 42

Engineering Data sheet ......................................................................................................................... 43

Databases .............................................................................................................................................. 47

User Database ................................................................................................................................... 48

Components .................................................................................................................................. 48

Tubes Database ............................................................................................................................. 49

Overall Heat Transfer Coefficient (Uo) Database ......................................................................... 50

Software Databases .......................................................................................................................... 51

Fouling Factors Database .............................................................................................................. 51

Tube Counts .................................................................................................................................. 52

Overall Heat Transfer Coefficients ................................................................................................ 53

Tools ...................................................................................................................................................... 54

Import ............................................................................................................................................... 54

Ms Excel ........................................................................................................................................ 54

Physical properties file .................................................................................................................. 55

Export ................................................................................................................................................ 57

MS Excel ........................................................................................................................................ 57

Engineering Data sheet ................................................................................................................. 58

Save/Load Project ............................................................................................................................. 58

Test Software .................................................................................................................................... 59

Troubleshooting Errors ..................................................................................................................... 60
http://www.webbusterz.com/http://www.webbusterz.com/http://www.webbusterz.net/http://www.webbusterz.net/http://www.webbusterz.net/http://www.webbusterz.com/

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About

Welcome to S&THex

This help file will explain in details all software features and any common errors that the

software may generate.

S&THex is a software tool that is made to demonstrate the chemical design and ratingcalculations of Shell & Tube Heat Exchangers.

The software unlike other tools, ensures that the calculations are performed step by step to

help in understanding the calculations.

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Version HistoryProduct minor revisions have been omitted from version history

S&THex v1.6 May 2010

Physical properties database separate interface

Export Physical properties to Ms Excel or XML file.

Import Physical properties from XML file.

Export Summary to Shell & Tube Engineering Data sheet to Ms Excel or pdf format

Fouling Factors

Improved user interface

Fixed few programming bugs

S&THex v1.5 July 2007

Added Fixed Tube sheet tube counts

Added general Tube SizesAdded Rating mode

Added Overall heat transfer coefficient calculations for clean and fouled conditions

Added Effectiveness, Number of transfer units and Thermal capacity ratio calculation

Added Pumping power calculation

Added the ability to enter Nusselt number in the correlations section

Added Gnielinski correlation to tube side



S&THex v1.4 July 2005

Added Software property estimation database (liquids property estimation only)

Added Overall Heat Transfer Coefficients Table

Added new saving function

Ability to import and export to Microsoft Excel


Estimation of Jh (heat transfer factor) - in correlations section

Added Shell/Nozzle/Channel/Head/Tube sheet Thickness Calculation


S&THex v1.3 May 2004

Added Databases (empty user databases)

Improved saving functionality

Added print screen functions

Fixed some common programming bugs

S&THex v1.2 Feb 2004

Added English (U.S. Units)

Added Shell diameter calculation

Added Scale resistance calculation/calculator

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Added Nozzle pressure drop calculation/calculators

Added drawing summary

Added some mechanical calculation

S&THex v1.1 Dec 2003Improved software interface

Added more correlations

S&THex v1.0 Jan 2003

First Release

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License Agreement

Use of SHELL & TUBE HEAT EXCHANGER DESIGN [S&THex] (This SOFTWARE) is contingent on your

agreement to the following terms:

1. GRANT OF LICENSE

The AUTHOR of this SOFTWARE (Khaled Aljundi) and WeBBusterZ Engineering Software

(WeBBusterZ or webbusterz.com/webbusterz.net/webbusterz.co.uk), grants you a limited, non-

exclusive license to use the SOFTWARE if you have purchased a copy or obtained the demo version.

2. DISCLAIMER:

While reasonable care has been exercised in the collection of data and testing of this software,

WeBBusterZ Engineering Software (WeBBusterZ or

webbusterz.com/webbusterz.net/webbusterz.co.uk) and Khaled Aljundi (the AUTHOR of this

software) disclaims any warranty, expressed or implied, as to the accuracy or reliability of the data

or calculations contained therein.

The physical properties obtained from this software yield approximate results, which will not alwaysbe suitable for every application. The software is designed for use by trained professional personnel

and is not a substitute for sound professional judgment. It is the sole responsibility of the user to

validate the data presented by this software and to determine whether the results are accurate and

suitable for any specific purpose. No guarantee of accuracy or fitness for any purpose is expressed or

implied. WeBBusterZ strongly recommends that the data be checked against other sources and/or

methods before use and application.

THE SOFTWARE IS PROVIDED AS IS WITHOUT WARRANTY OF ANY KIND. TO THE MAXIMUM EXTENT

PERMITTED BY APPLICABLE LAW, (WeBBusterZ or

webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR FURTHER DISCLAIMS ALL

WARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY,

FITNESS FOR A PARTICULAR PURPOSE, AND NON INFRINGEMENT. THE ENTIRE RISK ARISING OUT OFTHE USE OR PERFORMANCE OF THE PRODUCT AND DOCUMENTATION REMAINS WITH RECIPIENT.

TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL (WeBBusterZ or

webbusterz.com/webbusterz.net/webbusterz.co.uk) OR THE AUTHOR BE LIABLE FOR ANY

CONSEQUENTIAL, INCIDENTAL, DIRECT, INDIRECT, SPECIAL, PUNITIVE, OR OTHER DAMAGES

WHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS,

BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR OTHER PECUNIARY LOSS) ARISING

OUT OF THIS AGREEMENT OR THE USE OF OR INABILITY TO USE THE PRODUCT, EVEN IF (WeBBusterZ

or webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR HAS BEEN ADVISED OF

THE POSSIBILITY OF SUCH DAMAGES THE SOFTWARE IS PROVIDED AS IS WITHOUT WARRANTY OF

ANY KIND. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, (WeBBusterZ or

webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR FURTHER DISCLAIMS ALLWARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY,

FITNESS FOR A PARTICULAR PURPOSE, AND NON INFRINGEMENT. THE ENTIRE RISK ARISING OUT OF

THE USE OR PERFORMANCE OF THE PRODUCT AND DOCUMENTATION REMAINS WITH RECIPIENT.

TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL (WeBBusterZ or

webbusterz.com/webbusterz.net/webbusterz.co.uk) OR THE AUTHOR BE LIABLE FOR ANY

CONSEQUENTIAL, INCIDENTAL, DIRECT, INDIRECT, SPECIAL, PUNITIVE, OR OTHER DAMAGES

WHATSOEVER (INCLUDING, WITHOUT LIMITATION, DAMAGES FOR LOSS OF BUSINESS PROFITS,

BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION, OR OTHER PECUNIARY LOSS) ARISING

OUT OF THIS AGREEMENT OR THE USE OF OR INABILITY TO USE THE PRODUCT, EVEN IF (WeBBusterZ

or webbusterz.com/webbusterz.net/webbusterz.co.uk) AND THE AUTHOR HAS BEEN ADVISED OF

THE POSSIBILITY OF SUCH DAMAGES

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LICENSE:

3. SCOPE OF GRANT

You may not reverse engineer, decompile or disassemble the SOFTWARE. WeBBusterZ and the

AUTHOR shall retain title and all ownership rights to the SOFTWARE.

4. COPYRIGHT

This SOFTWARE is protected by copyright laws and international copyright

treaties, as well as other intellectual property laws and treaties.

5. MAINTENANCE

WeBBusterZ and the AUTHOR are not obligated to provide maintenance or updates for the

SOFTWARE. However, any maintenance or updates provided by WeBBusterZ and the AUTHOR shall

be covered by this Agreement.

6. DISTRIBUTION

The Demo version of this SOFTWARE may be freely distributed provided that it is not modified and

the original archive remains intact with all accompanying files, and provided that no fee is charged.

Should a fee be charged or any of the distribution

package need to be modified you must contact WEBBUSTERZ for explicit written permission.

YOU MUST AGREE TO AND ACCEPT THESE TERMS IF YOU WISH TO USE THIS SOFTWARE

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System Requirements

S&THex needs the following computer configuration to run:

Microsoft Windows operating system.64MB RAM;

30MB free disk space;

.Net Framework

Tested Windows XP, Windows Vista & Windows 7.

Acknowledgements

1. Standards of Tubular Exchanger Manufacturers Association, 6th Edition, TEMA Incorporated,

Tarry town, Newyork, 1978

2. Sinnott, R.K., Coulson and Richardson's Chemical Engineering Design, Vol. 6 , Third edition,

Butterworth-Heinemann

3. D. Q. Kern, Process Heat Transfer, McGraw-Hill, International Edition, 19504

Software Support

The support provided with this software is limited to NON Technical software issues. Please onlycontact us if you would like to report a software bug or problem.

It is highly recommended that you test the demo version of this software before purchasing the full

version.

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Main Screen

This will guide you through how to use the software, and how to avoid errors.

S&THex is easy to use as long as you follow the instructions provided in this document:

All calculations performed and screen captured are for demonstrationpurpose only and

shouldn't be used as a reference. Many screens have been modified due to

upgrades to newer version.

The software currently supports two units of measurement; S.I units and English (U.S) units.

The software will use S.I units as default units. Before proceeding to do any analysis you

must set the units of measurement.

You have now different options to proceed.

1. You can load components from your user database.

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2. You can load components from the software database

3. You can enter components to the software manually

To load components from your user database, point to Database located at the top menu

then select User. Your components are located under Components.

To load components from the software database (contains 1495 components) click on the

button labelled Estimation or simple point your cursor to Database and select

Software.

If you are entering the data manually, click on the button labelled Start

Design Mode

Tool bar

From the left

1. New - This button will clear all text boxes for a new project.2. Open- Load your saved project3. Save - save your project4. Back to main - The arrow will show the software main screen5. Import an XML format file or a physical properties file6. Import from Microsoft Excel7. Help - This will access this help file.8. Steps Navigation - Will show the window below.

Al l but tons are numbered and m ust be cl icked in ord er to avoid errors.

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Step 1

1. Enter Shell/Tube side components

2. Select physical state

3. Temperatures, units - 'C, 'K if using SI units in this case.

4. Only one check box from either the Shell side or Tube side can be checked - this will

allow for the Temperature prediction! - You can only ask the software to estimate only

one temperature on both shell/tube sides.

5. Enter Flow rate - in kg/hr or m3/hr

6. Only one check box from either the Shell side or Tube side can be checked if you want to

calculate an unknown flow rate.

7. Click the "Done" button.

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Step 2

1. Enter ALL values2. You can check the checkboxes to calculate Prandtl Number.3. If you have e.g. Steam then you must check the checkbox to enter the Specific Enthalpy

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Step 3

1. Click the "Calculate" button to calculate the duty2. Enter assumed Uo value - this can also be obtained from Uo database by clicking "Open

Database"3. This will show as below - every entry you select will be automatically aligned to the opposite one

in the database.

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Step 4

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1. Enter the Shell Diameter - Values can be found from literature. However the Shell

Diameter (Ds) and the Bundle Diameter (Db) can be estimated if the check box is

checked the screen below would appear. You can adjust the clearance value by checking

the "adjust clearance check box" then enter the clearance value and click the "adjustbutton", click the "Back button" to send the Ds value to the main screen.

2. Click "Done" button

3. If you click on "Standard pipe sizes" the screen below will appear, you can also find the

sizes you need if you are using fixed tube sheet heat exchanger

The tube counts for thi s can be found if you go to the main screen then cli ck on " Tube

counts"

Step 5

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1. Select Flow profile then click "Calculate" button2. Select to either enter or estimate the true temperature correction factor then click "Calculate"

button

Step 6

1. Calculate the Heat Transfer Area2. Also in some cases if any of the checkboxes in step1 was checked for estimating the Flow rate,then another "Calculate" button will appear for this purpose as shown below

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Step 7

1. All you need to do here is to click on the calculate button.

2. A check box to adjust the Number of Tubes will appear.

3. Adjust the Number of Tubes and click on the Calculate button again to re-calculate the

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rest of the information.

4. When you click the Calculate button the screen below will also popup - Click on calculate

to calculate the shell diameter (you can choose to adjust the clearance value by checking

the check box and entering the new value then click on Adjust button

5. If the Checkbox for estimating the initial Design Overall Coefficient (Ud), the screen

below will appear - Click the "Calculate" button to estimate.

Note: The Ud estimation must be completed in order to enable the estimation of the dirt

factor in later step.

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Step 8

1. Click the "Calculate" buttons in order2. When Correlation Screen appears select the correlation.

o First decide if you are ignoring the viscosity at wall or no - if it's ignored then check thecheckbox provided.

o For this case - Check the checkbox to calculate the Jh (heat transfer factor) - You canalso select to enter the Nusselt number if you prefer

o Click "Done" to go back to Step 8 Screen and calculate the Heat transfer coefficient

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Step 9

1. Select the Baffle cut and Type then click on the Done button to calculate the Cut.

2. Baffle diameter can be estimated after select (Pipe or Plate Shells).

3. You can edit the Baffle diameter value by checking the check box to edit the clearance,

enter the value then click the "Calculate button" to calculate the Baffle diameter.

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Step 10

1. Select a correlation to enable the calculation of the Heat Transfer Coefficient.

2. The same procedure will apply for the correlation screen below

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3. You can estimate the Scale resistance or Dirt factor. A screen like the one below will

appear.

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Step 11

Enter the material of construction and the thermal conductivity then click calculate.

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Step 12

1. Jf is a dimensionless friction factor (the same as the friction factor for pipes) and can be

obtained from literature (e.g. Reynolds number vs. Jf Charts).

2. Enter Jf and click the Calculate button.

Note: Shell & Tube sides Nozzles pressure drop can be estimated by checking the check

boxes provided. The screens below would appear.

3. Clicking on the other data button; will enable you to calculate (tube holes in baffles

diameter, shell thickness, number of tie rods & diameter and baffle plate thickness). The

estimations only are in fact recommendations based on TEMA Standards, so please check

with the manufacturers for accuracy. The screen for "other data" can be seen below

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Pumping Power can also be calculated for fluids only

Step 13

This Part of the software will only do some basic mechanical calculationsAfter filling in all the data required the results button must be clicked to see the results.

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Results screensClick the calculate button to show all answers

Because the screen below only makes recommendations, if your Ds value is < 6 in thesoftware won't be able to generate the results.

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Summary

For Engineering data sheet please click here

1. Note that every time you make a change to any entry in the problem specification you

need to re-click the show button and scroll down to the new set of results

2. The summary also can be seen with only basic Graphical illustration, other CAD or

drawing packages should be used for more accurate illustrations.

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Rating ModeFluids Rating only!

The software will present you with 9 steps, the first 4 are intended to add the rating problem data, thelast 4 are the rating calculations.

Step 1

Enter all data in step 1

To change the temperature from "'C" to "'K" in SI measurement units you must check the checkbox

Click step 2 to continue

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Step 3

Select flow arrangement

You can choose to calculate the area or duty however since this is rating of existing heatexchanger it's always better to have all such information available at hand, this will help in

producing better results

Thermal conductivity value for materials of constructions are available in literature

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Step 4

Enter exchanger layout and type

Enter Tube details then click "1- Done" button - this will calculate the inside diameter

Clicking on the "Standard pipe sizes" to show the pipe sizes database

Enter Shell diameter

Step 5

Enter all baffle information

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Step 6

This is the tube side rating calculation screen - You must click the buttons in order

Before clicking on "3- Calculate" button the check box must be checked to use a correlation tocalculate Nusselt number

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Step 7

This is the shell side rating calculation screen

Before clicking on "4- Calculate" button the check box must be checked to use a correlation tocalculate nusselt number

Step 8

The results screen below is revealed after clicking of the Calculate button present in step 7

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Step 9

This is the final step to calculate the pressure drops, this step also account for the inlet and exitlosses

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Summary

Summary screen - Click the "Show" button to show thee summary of results

If you make changes to the results you will need to click on the "Show" button again and scrolldown to the new set of results

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Zoom in/outExport html

format

Print

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The Ms Excel should look the same as above see below

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Databases

The software offers a collection of databases for your own convenience, the screen below can

be accessed via the main screen buy clicking on the button or

Please note: all estimation techniques wil l sometimes resul t in error factor. Professional

judgment should be exercised wi th reference to al l estimation made. We recommend

checking properties against a li terature source if in doubt.

For Mixture Estimation - The following limitations apply:

o Mixture Viscosity is only valid for Organic liquids only,o Mixture Thermal Conductivity only valid for non polar liquids only

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User Database

All data are stored in sthex.mdb file and this can file can also be accessed from MicrosoftAccess. if you prefer.

Components

The database function is to help in saving you time through projects. All you need to do is

enter the component and its physical properties. When you are done, add the component. As

you progress through adding the components you can load any component to any side (i.e.

Hot or Cold side) by clicking the appropriate button.

Before loading any component always make sure that you have selected the correct units of

measurements from the software's main screen. This is simply to avoid conflicts between

units of measurements.

Edit, Delete Refresh, Find, Filter, Sort ....etc.All above mentioned are there for your convenience and they can be used as you add more items tothe software.

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Tubes Database

The tube database has similar functions to the components database - again the most important issueis the units,

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Overall Heat Transfer Coefficient (Uo) Database

This database is extra, the software now have values Uo and they can be accessed from the main

screen.The database should be used the same way as the components database, all buttons have the samefunctions.

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Tube Counts

Tube Counts can be accessed through the main screen, The counts below are valid for FIXED TUBE SHEET EXCHANGERS

The database can be navigated by clicking on the "Next or Prev" buttons

If you want a copy to print out, you can click on the PDF image button to open up the pdf file inAdobe viewer

The find button can be used to search the database, this can be performed by searching by field

Data Grid button will adjust the columns based on the longest field

You can scroll to view records Horizontally as well as Vertically

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Overall Heat Transfer Coefficients

Can be accessed from the software during design mode or the main screen.

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Physical properties file

The second method is to import from an XML file. This file is associated with the Physical propertiesdatabase. Once you followed the instructions in physical properties user guide and generate an XMLfile you will need to import it using the tool below.

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The first step is to browse to the XML file, you will need to click on the "Browse" button then find theXML file, the browse will usually start from the software default installation directory, so if you savedyour properties file in the same directory you it should look similar to the one below.

When you open the file all the properties you generated will appear as below

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Select the component and the units of measurements then assign the components toShell/Tube/Hot/Cold side.

Then go to the main screen and continue to Step 1. All the properties should be loaded in Step 2.

Export

MS Excel

This function will only work if you have Microsoft Excel installed on your PC!

The Export wizard can only export your summary of results obtained from the summary screen notthe graphical summary.1. Click on "Show" button to see the summary first.2. Click on "Export" button to export your results.

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Engineering Data sheet

For Exporting to Engineering data sheet please click here

Save/Load Project

Save Function 1

This will only save your values not your results.

Saving files

1. Enter the Project Name2. Enter the location of the project including your file nameThis can be like: C:\Program Files\webbusterz\project1.txtWhere project1.txt is the name of your project file.3. Click "Save" button

Loading Files

1. Click "Open" to select the file (e.g. project1.txt)2. Click "Open" button again to load your file

Save Function 2

Will save your results and values.Saving files1. Click "Browse to save" button - and type in the name of your project2. Click "save" to go back to saving screen3. Click "Save" button on saving screen to save.

Loading files1. Click "Browse to open" button - this button will be enabled when you select "open" from the file

menu on the main screen.2. Select your file e.g. project1.dat3. Click "open" to go back.4. Click "Open" button to load your project.

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Troubleshooting Errors

Errors that may occur and how to handle them

Division by zero

This error may occur under different conditions, if this error occur while thermal calculations

are performed then check the figures you entered in to the data entry screens. It's more likely

that you forgot to enter a figure or you entered an incorrect figure format.

Make sure that all your text boxes are filled correctly and you are clicking all buttons in

order.

Cli ck on Calculate button and the resul ts given is Zero

Try to close the screen then reload it again and click the calculate button, this method will

refresh the software controls.

Documents

STHexhelp