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\
|
=
1 2
2 1
t t
T T
R
=
1 1
2 2
t T
t t
P
=
Process Engineering Manual
Heat Exchanger Monitoring
Compiled by Sabri Ahmad
.t
1
= outlet temperature of tubeside stream
For R unequal to 1, compute:
N
P
RP
/ 1
1
1
|
\
|
=
R
S
1
( )
|
|
\
|
+ + +
+ +
\
|
+
=
) 1 1 ( 2
) 1 1 ( 2
ln 1
1
1
ln 1
2
2
2
R R S
R R S
R
RS
S
R
F
c
Process Engineering Manual
Heat Exchanger Monitoring
Compiled by Sabri Ahmad
For R = 1, compute:
Effectiveness Method
In this method, the dirty coefficient is computed from the heat exchange effectiveness
which is defined as the ratio of heat duty to the maximum possible heat transfer. The
latter is the rate of heat transfer that would occur in a counter-current flow heat exchanger
having infinite heat transfer surface area. In such an exchanger, one of the fluid streams
will gain or lose heat until it outlet temperature equals the inlet temperature of the other
stream. The stream that experiences this maximum temperature change is the one that is
having the smaller value of C = mC
p
, as can be seen from the heat balance equations from
the two streams. Thus if the hot stream has the lower value of C then T
2
= t
1
. The
maximum possible heat transfer is given by:
Q
max
= WC
p
(T
1
T
2
) = WC
p
(T
1
t
1
) = C
min
(T
1
t
1
)
On the other hand, if the cold fluid has the lower value of C, then t
2
= T
1
and
Q
max
= wc
p
(t
2
t
1
) = wc
p
(T
1
t
1
) = C
min
(T
1
t
1
)
In either case
Q
max
= C
min
(T
1
t
1
) = C
min
max
Where
max
is the maximum possible temperature difference that can be formed from the
terminal temperatures.
By definition, the effectiveness is given by,
If the hot stream has the lower value of C, then
If the cold stream has the lower value of C, then
For a given type of heat exchanger, depends only on two parameters, r and NTU where
P P N
P
S
+
=
) 1 (
|
|
\
|
+
=
2 ) 1 ( 2
2 ) 1 ( 2
ln ) 1 (
2
S S
S S
S
S
F
c
( )
( )
1 1
2 1
t T
T T
=
( )
( )
1 1
1 2
t T
t t
=
Process Engineering Manual
Heat Exchanger Monitoring
Compiled by Sabri Ahmad
NTU stands for number of transfer unit. The relationships between effectiveness, r and
NTU for shell & tube heat exchangers are given below.
For counter-current and r < 1
If r = 1 then
For co-current or parallel flow
For 1-2 exchanger
For N-2N exchanger (N= number of shell passes) and r < 1,
If r = 1 then effectiveness is given by
max min max
T C
Q
Q
Q
= =
max
min
C
C
r =
min
C
UA
NTU =
[ ]
[ ] ) 1 ( exp 1
) 1 ( exp 1
r NTU r
r NTU
=
NTU
NTU
+
=
1
[ ]
r
r NTU
+
+
=
1
) 1 ( exp 1
[ ]
[ ]
(
+
+ +
=
NTU
NTU
r
exp 1
exp 1
1
2
2
1 r + =
|
|
\
|
|
|
\
|
=
r
r
r
N
N
1
1
1
1
1
) 1 ( 1 +
=
N
N
Process Engineering Manual
Heat Exchanger Monitoring
Compiled by Sabri Ahmad
Where is the effectiveness for a 1-2 exchanger with the same value of r but NTU is
given by
The dirty overall coefficient is determined from the NTU correlation since the surface
area and C
min
are known. The correlation for 1-2 exchanger, for example, can be re-
arranged as shown below.
Then U
d
can be computed from
Overall Clean Heat Transfer Coefficient
Clean Heat Transfer Coefficient U
c
is computed from the individual film heat transfer
coefficient of the shellside and tubeside streams.
The individual film heat transfer coefficients are computed either graphically or using
correlation below:
For tubeside,
For cooling water, the following simplified correlation can be used.
Where hi = tubeside heat transfer coefficient, W/m
2o
C
T = average temperature,
o
C
G
t
= mass velocity, kg/m
2
s per tube
U
t
= water velocity, m/s = G
t
/density
D
i
= tube inside diameter, mm
i i
o
o c
D h
D
h U
+ =
1 1
14 . 0
3 / 1
ln 85 . 0 287 . 4 exp
|
|
\
|
|
\
|
|
|
\
|
|
|
\
|
|
|
\
|
+ =
w i
t i
i
K
c
D
K G D
h
min
NC
UA
NTU =
( )
8 . 0
2 . 0
02 . 0 35 . 1 4200
t
i
i
U
D
T
h
+
=
(
+ +
+
=
) 1 ( / 2
) 1 ( / 2
ln
1
r
r
NTU
A
NTUC
U
d
min
=
Process Engineering Manual
Heat Exchanger Monitoring
Compiled by Sabri Ahmad
The shellside film coefficient can be obtained from
The shellside equivalent diameter is computed as below
For square pitch,
For triangular pitch,
The shellside mass velocity G
s
is computed using correlation below.
Where W
s
= mass flowrate of shellside stream, Kg/s
P
t
= tube pitch, m
B = baffle spacing, m
S = shell diameter, m
D
e
= equivalent diameter, m
D
o
= tube outside diameter, m
D
i
= tube inside diameter, m
Dirt Factor Trending
Knowing the overall dirty coefficient and the clean coefficient then the dirt factor can be
computed. For monitoring purposes, we can either plot the dirt factor over time period or
alternatively the reciprocal of dirt factor over time.
Future performance of the exchanger can be predicted by determining the correlation that
represents the relationship of dirt factor (or the reciprocal) versus time period (e.g. days).
Dirt factor of greater than the design value shall indicate fouling and deserves
investigation especially if this occurs at the start-of-run. The performance of the
exchanger is considered normal if the dirt factor remains below the design value over the
monitoring period.
14 . 0
3 / 1
ln 5195 . 0 665 . 0 exp
|
|
\
|
|
\
|
|
|
\
|
|
|
\
|
|
|
\
|
+ =
w e
s e
o
K
c
D
K G D
h
( )
2 2
785 . 0
27 . 1
o t
o
e
D P
D
D =
( )
2 2
917 . 0
1 . 1
o t
o
e
D P
D
D =
( )BS D P
P
W G
o t
t
s s
=
Process Engineering Manual
Heat Exchanger Monitoring
Compiled by Sabri Ahmad