BAB TUGAS KHUSUS HE Eng

REPORT
Cepu Oil and Gas Training Center (PUSDIKLAT)

1 – 30 January 2016
CHAPTER I
PRELIMINARY
1.1. BACKGROUND
In general, every industry, many involving heat transfer process. Heat
exchanger is a support tool in the process of heat transfer. Heat exchangers have an
important role in controling the temperature of the flow before the inflow into the
next process. In general, processing crude oil at the refinery unit in "Pusdiklat Migas
Cepu" using atmospheric distillation process, the process is based on differences in
boiling point at a pressure of 1 atm. In outline the process in the processing of crude
oil consists of a heat treatment (heat exchanger and furnace), and distillation.
Type Heat exchangers are used in Cepu Oil and Gas Training Center is a
Shell and Tube Heat Exchanger and the type of flow is Cross Current. HE consist of
small pipes (tube) is inserted parallel to one another are in a shell (shell). Tube is
used as a medium through which the crude oil, and the shell as a medium through
which the heating fluid (naphtha, diesel oil and residue). Heat exchanger 3 in the
refinery unit has a function to heat the incoming feed in the form of crude oil using
diesel as heating products.
Heat exchanger when it is operated in a certain period of time it will decrease
its efficiency. This can be caused by several factors, among others; the formation of
scale, corrosion, leakage, and fluid flow which causes friction against the walls of
the appliance. This decrease in efficiency can be seen from parameters such as
pressure drop and the dirt factor (Rd) exceeds the specified price. To maintain
optimal conditions it is necessary to redesign the heat exchanger.
1.2. FORMULATION OF PROBLEM
In this task will be done redesign Heat Exchanger 3 based on the data that
can be directly from the field using Rd (dirt factor / fouling factor), and the pressure
drop of the Heat Exchanger 3. The results obtained will be compared with the
parameters of allowable limits. With this comparison are expected to know the
design of Heat Exchanger 3 that has existed in the appropriate design, so that the heat
exchanger 3 can be in decent condition or optimum unit refinery in Cepu Oil and Gas
Training Center
Chemical Engineering Yulira Kus Rendra 1

University Muhammadiyah of Surakarta D500122002
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1 – 30 January 2016
1.3. PURPOSE
Redesign HE-3 is based on the existing data in the field with parameter dirt
factor (Rd), and pressure drop

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1 – 30 January 2016
CHAPTER II
LITERATURE REVIEW
2.1. Heat Transfer Mechanism
Heat transfer Equipment is used for a variety of industrial processes, this
tool serves to transfer heat between two fluids where the fluid has a higher
temperature will provide heat at a lower temperature fluid. From the use and
function, heat transfer apparatus have different designations include: heat
exchanger, heating (heater), conditioner (cooler), condenser, reboiler, and others.
There are three basic mechanisms of heat transfer, namely:
1. Conduction
A heat transfer through a particular material. The process of heat
transfer that occurs between molecules that are close together between each
other and are not followed by the movement of these molecules physically. The
molecules of hot objects vibrate more rapidly than molecules vibrating body in
a cold state. Rapid vibrations of this power is delegated to the surrounding
molecules, causing vibrations faster and will provide heat.
2. Convection
Convection is heat transfer between the hot and cold of a fluid due to
the mixing process or it can be said that the heat transfer occurs due to the
movement of the medium. Convection heat transfer can be classified into two
parts:
a. Natural or free convection, where the movement of the medium caused by
the difference in density or temperature of the medium.
b. Forced convection, where the movement of the medium caused by the aid
workers from outside, for example, stirring.
3. Radiation
A heat transfer without going through the media. One can conduct
energy from one place to another (from a hot object to a cold object) with
electromagnetic waves in which this energy is converted into heat when energy
is absorbed by another object

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1 – 30 January 2016
2.2. Type of Heat Exchanger

2.2.1. Type HE Based TEMA Standard
Based on the standard TEMA (Tubular Exchanger Manufacturer
Association) Heat Exchanger can be grouped in the planning and
preparation, namely:
1. R Class
Usually Heat Exchangers Shell and Tube-type, and is used for
processing oil and gas industry
2. B Class
Heat Exchanger class is commonly used for chemical processes.
3. C Class
Heat Exchanger grade is used for general needs.
2.2.2. Type HE Based on Construction
Based on construction, Heat Exchanger divided in many type,
namely:
1. Fixed Tube Sheet
Is one form of construction, in which the tube sheet that all the two
were in the shell.
2. Floating Head
Is a form of construction, where one float on a tube sheet are at the
other shell.
3. U-Tube Bundle
Is a form of construction, where only one tube sheet is required and
the tube shell as well as all forms of U.
4. Double Pipe Heat Exchanger
HE with the double pipe system, Shape of HE in which there is a
tool in another big pipe concentric pipes, which pipacairan flow between
the outer annular portion. Use of Double-pipe heat exchangers to
substances that have low heat transfer system.

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1 – 30 January 2016
5. Kettle
For the construction can be seen clearly on its Shell, which Shell
is most used as a steam chamber so that it can provide an opportunity to
better fluid evaporation. Boiled liquid located in Shell, while the liquid
used for heating are in the Tube.
6. Pipe Coil
This type is made of curved pipe that forms the spiral, usually
immersed in the liquid and heated with steam heating medium. This type
is used as a heater, Instant confirmation on landfilling a tank of crude oil
or heavy oil.
2.3. Component of Heat Exchanger

2.3.1. Tube
Tube is used as a heat conductor medium between the fluid and the
cold fluid. Tube is based on the size of the pipe diameter is divided into,
the outer diameter of the tube is measured by rooms, whereas the standard
thickness using BWG (Birmingham Wire Gages). There are two types of
tube that is plain and finned tube. Some tube assembled into a unit called
tube bundle. The layout of the mounting tube there are four kinds:
Figure 2.1 Layout Tube
a) Square Pitch
In type II center point 90 ° angle (perpendicular) to form a square
perpendicular to fluid flow.

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1 – 30 January 2016
b) Triangular Pitch
Tube configuration is an equilateral triangle (the central point forming
an angle of 60 °) Triangular Pitch has a higher heat transfer than Square
Pitch.
c) Square Pitch Rotated
Configuring tube shaped like rectangular tiles.
d) Triangular Pitch with Cleaning Lines
Triangular configuration equipped with dry lines to facilitate the
cleaning tool.
2.3.2. Tube Bundle
Tube Bundle is made up mutually concatenated tube between the tip
to the base of the tube in the first or second sheet (sheet). Tube bundle an
important circuit in the heat exchanger, and the determination of the
capacity of the equipment.
2.3.3. Tube Sheet
Is a discovery or binding tube ends. Tube sheet made of material with
thickness and type of which depends on a certain kind of liquid flowing in
the equipment.
2.3.4. Shell
Shell is a cylinder that is located outside in the heat exchanger. Shell
shape size (plate thickness and diameter) is limited by considerations
reviews such as handling capabilities in the areas of maintenance and
cleaning facilities.
2.3.5. Baffle Plat
A baffle plate mounted on the bulkhead as in a shell tube. Their baffle
(baffle) causes fluid flow in the shell becomes longer and winding, so the
heat transfer is more perfect and can be arranged.
2.3.6. Tie Rod
is a round-shaped iron rods which have rooms and has a threaded at
both ends and placed in a tube sheet (tube sheet) allows you to:

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1 – 30 January 2016
a. Maintaining a long tube that is always between two tube sheet

b. Keeping the distance between the baffle plates.
c. Keep and maintain the connection tube.
d. Changes shape when underway or removal of the tube bundle to be
repaired
2.3.7. Impingement Plate
To protect the tube from the abrasion of solid particles into the shell.
2.4.Selection Fluid Shell and Tube
Factors that influence the choice of fluid in the shell and tube, among others:
 Clean ability
When compared to how clean the tube and shell, the shell side cleaning
much more difficult. To clean the fluid that normally flowed next to the shell
and dirty fluid through the tube. Dirty fluid is passed through the tube for tube-
tube can easily be cleaned.
 Corrosive
The problem of corrosion is affected by the use of metal alloys. The
metal alloy is expensive therefore corrosive fluid flowed through a tube for
saving costs incurred due to damage to the shell.
 Pressure
High pressure fluid is passed on tuba because when passed in diameter
and thickness of the shell requires more that costs more expensive.
 Temperature
Fluid with high temperature is passed to the tube as the heat is transferred
entirely to the outside surface of the tube or in the direction of the shell so that
it will be absorbed completely by the fluid flowing in the shell. If the fluid with
higher temperature is passed to the shell, the heat transfer is not only done in
the direction of the tube, but there is the possibility of heat transfer also occurs
toward the outside of the shell (to the environment).
 Quantity
Fluid which has a large volume is passed through the tube to maximize
heat transfer process that occurs.

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1 – 30 January 2016
 Sediment/ Suspended Solid / Fouling

Fluid containing sediment / suspended solid or which cause fouling
should be streamed on the tube so that the tubes be easily cleaned. If the fluid
contains sediment flowed in the shell, then the sediment / dry fouling on the
shell side becomes impossible without unplugging Tube Bundle.
 Viscosity
The fluid is viscous or has a low transfer rate (lower rate) is passed
through the shell because it can use the baffle.
 Pressure drop
Laying of fluid in the body will be easier in calculating pressure drop.
The pressure drop that occurs in each of the different streams within the
limits permitted, namely:
- For stream vapor and gas : ΔP between 0.5 – 2.0 psi
- For stream liquid : ΔP between 5 - 10 psi
Both of these provisions must be considered both in conducting the
evaluation and analysis of the performance of a heat transfer apparatus.
2.5. GANGGUAN PADA HEAT EXCHANGER
2.3.8. Leaks Tube
This is due to the looseness of tube sheet (tube sheet) and the tube
does not expand at the same time. This leakage can cause contamination of
the product. Leakage tube marked with a flash point and can be overcome
by changing operating conditions, stop the inflow of shell and tube and held
improvement.
2.3.9. Leaks Shell
It is characterized by the release of smoke or fluid in the outer shell
plate. This can be overcome by spraying with water, changing the pressure
and temperature conditions, stopping HE, and close the tap in the entry and
tap out.
2.3.10. Needs Disturbance Shell
This happens because the rest of the lower temperatures (below the
pour point) resulting in residual clots and is characterized by a temperature

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1 – 30 January 2016
drop in crude oil from HE. So it can be overcome by injecting diesel fuel to
set by-pass residue that not all residues through HE
2.3.11. Moving tube Disturbance
This is due to the presence of impurities stuck including crude oil,
the crust due to high temperature, corrosion.

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CHAPTER III
METHODOLOGY
3.1 COLLECTING DATA
The collection of data for the design of Heat Exchanger-03 in Cepu Oil and
Gas refinery units obtained from:
1. Field Data
 Data of inlet temperature and outlet from shell.
 Data of inlet temperature and outlet from tube.
2. Control Room
 Data of capacity crude oil and solar produced.
3. Laboratories Unit refinery
Data of density
4. Literature books
Method for calculation (Process Heat Transfer-DQ Kern)

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1 – 30 January 2016
CHAPTER IV
HASIL DAN PEMBAHASAN
4.1 Data
T1= 397.760F T2= 330.80F
HE-3
(Counter-Current)
t2= 213.80F t1= 131.80F
Given:
Data of Heat Exchanger in Pusdiklat Migas Cepu
Specific
Temperature Specific
Capacity per day, Temperature gravity,
outlet, T2 gravity, SG
Vs (L/days) inlet, T1 (℃) SG
(℃) (℃ kg/m3)
60/60℉
SHELL (SOLAR)
205℃ = 170℃ =
156306 0.8466 0.8588
401℉ 338℉
TUBE (Crude Oil)

Specific
Temperature Specific
Capacity per day, Temperature gravity,
inlet, gravity, SG
Vm (L/days) outlet, t2 (℃) SG
t1 (℃) (℃ kg/m3)
60/60℉
56℃ = 1000C=
372000 0.839 0.8512
132.8℉ 2120F

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1 – 30 January 2016
4.2 Calculation to Redesign HE-3
Requirements that must be considered in the design of Heat Exchanger is;

a. Dirt factor (Rd) should count = Rd provisions, or Rd calculation
> 5-10% of Rd condition
b. The pressure difference (P) for fluid flow does not exceed 10 psi
Below is the calculation steps in designing the data reference HE HE-3.
1. Determine Flow Rate
Solar Crude Oil
WSolar = Vs 𝑥 SGs WCrude Oil = Vm 𝑥 SGm
156306 𝐿 1 hari 372000 𝐿 1 hari

Ws =[ ] [24 jam] x Wm =[ ] [24 jam] x
hari hari
kg lb kg lb
[1 ] 𝑥0.8588𝑥 [2.20462 ] [1 ] 𝑥0.8512𝑥 [2.20462 ]
L kg L kg
lb
lb Wm = 29089.7448
Ws = 12331.98 hr hr
2. Determine Cp
Solar Crude Oil
T1+T2 401℉+338℉ t1+t2 132.8℉+212℉
Tavg= = = 369.5℉ Tavg= = = 172.4℉
2 2 2 2
141,5 141,5
0
API = – 131,5 0
API = – 131,5
SGs60/60°F SGs60/60°F
141,5 141,5
0
API = – 131,5 0
API = – 131,5
0.8588 0.8512
0 0
API = 33.2486 API = 34.7194
from fig.4 Kern get Cp solar = from fig.4 Kern get Cp solar = 0.52
0.62

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1 – 30 January 2016
3. Determine value q solar and Crude Oil

qSolar = qCrude Oil
q s = Ws x cp x (T1-T2) q m = Wm x cp x (t2-t1)
lb btu lb btu
q s = 12331.98 x 0.62 lb°Fx q m = 29089.7448 hr x 0.52lb°F
hr
(401-338) °F x (132.8-212) °F
btu btu
q s = 1198032.052 q m = 1198032.52 hr
hr
so ...
Q = qs - qm
btu btu
Q = 1198032.052 - 1198032.052
hr hr
btu
Q=0 hr
 Losses
Q
Losses = qs x 100%
Losess = 0 %
 In balance condition
btu
Q = qsolar = qCrude Oil = 1198032.052 hr
4. Determine Condition HE
Transfer of heat to be supplied (solar as hot fluid)
It has been calculated in step 3
btu
q s = 1198032.052 hr
 Flow rate at cold fluid is Crude Oil

It has been calculated in step 1
lb
Wm = 29089.7448hr

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1 – 30 January 2016
5. Determine LMTD
Shell (Solar) Tube (Crude Oil) ∆𝐓
T1= 401 °F t2= 212°F ∆T = 189°F
T2= 338°F t1=132.8°F ∆t = 205.2°F
∆𝑇− ∆𝑡 183.96 °F− 199.62 °F

LMTD= ∆𝑇 = 183.96°F = 196.98°F
𝑙𝑛 𝑙𝑛
∆𝑡 199.62 °F
6. Determine factor correction real for LMTD (Ft)

 R
T1−T2
R= t2−t1
401 °F − 338 °F
R = 212 °F−132.8°F
From figure.18 Kern,
R = 0.79 relationship between R and S
get Ft = 0.98
t2−t1
 S = T1−t1
212 °F − 132.8°F
S= 338 °F−132.8°F
S = 0.29
Because Ft get = 0.98 based fig 18 Kern, so get HE with amount of (n)
pass in shell=1, and amount (n) pass in tube= 2 or more. To determine
amount (n) pas in tube actual, so used standardization amount number of
tubes (Nt) according table 9, Kern.
∆LMTD koreksi= LMTD x Ft = 196.98°F x 0.98 = 193.049 °F

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1 – 30 January 2016
7. Trial UD
From table 8 Kern, value Ud for feed solar (Heavy Organic) and
Crude oil (Heavy Organic) get UD= 10 – 40
 Assumption Ud= 10.1
btu
Q 1198032.052
A= Ud x = hr
= 602.1506 ft2
∆LMTD 10.1 x 196.98°F
At HE-3 ODtube 1 in, BWG=14, get

 ID shell= 0.834 in
 L = 10 ft
 a’t = 0.546 in2
 a’’t = 0.2618 lin ft, ft2 (Table 10, Kern)
A 602.1506 ft2
Nt= L x = = 230
a′′t 10 ft x 0.2618 lin ft,ft2
From table 9 Kern at 1 in OD tubes on 1.25 Triangular Pitch choosen :

Nt= 232, n= 4 pass, ID shell= 17.25 in
A Correction = Nt x L x a’’t = 232 x 10 ft x 0.2618 lin ft, ft2
= 607.376 ft2
btu
Q 1198032.052
hr
Ud Correction = A x =
∆LMTD koreksi 607.376 ft2 x 193.049 °F
=10.21
 Assumption B= 6.8 in
12 x L 12 x 10 ft
So (N+1) = = = 211
B 6.8
(N + 1) = 30, so amount of baffle = (360 -1) =210

 C’ = Pitch tube – OD tube = 1.25 – 1 = 0.25

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1 – 30 January 2016
Interpolate
Based data of viscosities of petroleum fraction, Kern. Get value
For 0API 28 : x = 10 and y = 23.6
For 0API 35 : x = 10 and y = 20
Solar Crude Oil
For 0API 28 get value µ = 0.85 For 0API 28 get value µ = 4.1
For 0API 35 get value µ = 0.3 For 0API 35 get value µ = 1.9
0 0
So interpolate for API So interpolate for API
33.2486 34.7195
35 − 33.247 0.3 − µs 35 − 34.719 1.9 − µm
= 0.3 −0.85 =
35−28 35−28 1.9 − 4.1
lb lb
µs = 0.46 cp x 2.42 hr .ft µm = 1.7 cp x 2.42 hr .ft
lb lb
µs = 1.1194 hr .ft µm = 4.346hr .ft
8. Calculate cross sectional area (a) at Shell and Tube

Shell Tube
IDs x C′ x B 𝑁𝑡 x a′t
as = at =
144 x Pt 144 x n
17.25 in x 0.25 in x 4 106 x 0.546 in2
as = at =
144 x 1.25 in 144 x 4
as = 0.343 ft 2
at = 0.439 ft2
9. Calculate mass velocity (G)

Shell Tube
Ws Wm
Gs = Gt =
as at
lb lb
12331.98 29089.7448
hr hr
Gs = Gt =
0.1974 𝑓𝑡 2 0.1023 ft2
lb lb
Gs = 35942.9123hr ft2 Gt = 66138.1hr ft2

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1 – 30 January 2016
10. Determine Reynold Number

Shell Tube
at ODt= 1 in and Pt= 1.25 at ODt = 1 in and BWG =14, so get
Triangular pitch so get De = 0,72 IDt= 0.834 in = 0.0695 ft
in = 0,06 ft (Based table 10, Kern)
(Based fig. 28, kern) IDt x Gt
R et = μm
De x Gs
R es = lb
μs [0,0695 ft ] x [284148.91 ]
hr ft2
R et = lb
lb 5.096
[0,06 ft] x [82356.15 ] ft hr
hr ft2
R es = lb
1.059
ft hr R et = 1057.48
R es = 1926.44
11. Calculate value jH

Shell Tube
jH = 24 (Based fig. 28, kern) L 10 ft

=
IDt 0,0695 ft
L
= 143.884
IDt
jH = 3.8 (Based fig. 24, kern)

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1 – 30 January 2016
cp x µs 1/3
12. Determine Prandtl ( )
k
Shell Tube
When condition : When condition:
Tc = 368.240F and 0API = 33.248 tc = 170.810F and 0API = 34.719
Btu Btu
Get value cp = 0.62 (from Get value cp = 0.52 0 (from fig.
lb .0 F lb . F
fig. 4, kern) and 4, kern) and

k = 0.071 (from fig. 1, kern) so ... k = 0.076 (from fig. 1, kern) so ...
cp x µs 1/3 0.62 x 1.059 1/3 cp x µs 1/3 0.52 x 5.096 1/3
( ) = ( ) ( ) = ( )
k 0.071 k 0.076
cp x µs 1 cp x µs 1
( )3 = 2.138 ( )3 = 3.0982
k k
13. Determine Coefficient Heat Transfer

Shell Tube
ho k cp x µs 1 hi k cp x µm 1
= jH x De x ( )3 = jH x IDt x ( )3
Φs k Φt k
ho 0.071 0.62 x 1.059 1/3 hi 0.0759 0.52 x 5.096 1/3
=35 x 0.06 ft x ( ) =12x0.0695 ftx ( )
Φs 0.0708 Φt 0.076
ho hi
= 60.2746 = 42.0560
Φs Φt
hio hi IDt
= Φs x ODt
Φt
hio 0.834 in
= 12.874x
Φt 1 in
hio
= 10.7373
Φt
14. Determine Temperature Wall Outside Tube (Tw)

ho
Tw = tc + ∅s
ho hio x (Tc – tc)
+
∅s ∅t
86.9331
Tw = 170.8160F + 86.9331+35.07476 x (368.240F – 170.8160F)
Tw = 338.576 0F

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1 – 30 January 2016
15. Calculate Value Φ

Shell Tube
at Tw= 311.4840F and 33.24 API at Tw= 311.4840F and 34.71 API
get get
µw = 0.58 centi pose (Fig. 14 Kern) µw = 0.45 centi pose (Fig. 14 Kern)
lb lb
µw = 1.422 µw = 1.1423
ft .hr ft .hr
µs µm
Φs = Φt =
µw µw
lb lb
1.059 5.096
Φs = hr .ft
lb Φt = hr .ft
lb
1.7608 1.4404
ft .hr ft .hr
Φs = 0.9670 Φt = 1.2057
16. Calculate Corrected Coefficient

Shell Tube
ho hio
ho = Φs x Φs hio = Φs x Φt
ho = 86.9331x 0.9312 hio = 35.07476x 1.1839

Btu Btu
ho = 58.7246 hr.ft2 .0 F hio = 12.9464hr.ft2 .0 F
17. Calculate Clean Overall (Uc)

hio x ho
Uc = hio+ho
btu
(41.5260 x 80.9599 )
hr°F ft2
Uc = btu
(41.5260 + 80.9599)
hr°F ft2
Uc = 10.6077
18. Calculate Dirt Factor (Rd)
uc−ud koreksi
Rd = uc x ud koreksi
27.44759−22.362 (btu/hr ft °F)
Rd = 27.44759 𝑥 22.362 btu/hr ft °F
Rd = 0.0036 hr ft2 °F/Btu

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1 – 30 January 2016
19. Calculate Pressure Drop

Shell Tube
f = 0.0024 (from fig.29, kern) f = 0.0019 (from fig.26, kern)
Φs = 0.9312 Φt = 1.1839
s = 0.75 ( from fig 6, kern) s = 0.78 ( from fig 6, kern)
Ds = IDs = 1.4375 ft D = IDt = 0.0695 ft
L n = nt = 1
N+1 = 12 x B
10 ft
N+1 = 12 x 0.33 ft
N+1 = 211
PT  Pt  Pr

f .G .DS .N  1
2
f .Gt2 .L.n
PS  S
Pt 
5.22.1010.De.s. S 5.22.1010.D.s. T
0.0024 x (82356.152 )x 1.4375 x 360 2 2 )x 10 x 4
∆Ps = ∆P 40,0019
.n vx (284148.91
.
10
5,22 x (10 )x 0.06 x 0.75 x 0.9312 Pr 5,22 x (10
t = . )x 0,0695 x 0.78 x 1.1839
10
s 2.g '
∆Ps = 0.415 psi ∆Pt = 0.1641 psi
20. Redesign HE-3

Capacity 300 m2
Shell side (solar) Tube side (Crude Oil)
HE 1-2 Shell and tube, triangular ODt = 1 in
pitch BWG = 14
IDs = 23.25 in IDt = 0,834 in
Baffle (B) = 6.8 in L = 10 ft
ns = 1 Pt. = 1,25 in
Amount Baffle= 210 Nt = 232
Rd calculated= 0.0036

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1 – 30 January 2016
Capacity 600 m2
Shell side (solar) Tube side (Crude Oil)
HE 1-2 Shell and tube, triangular ODt = 1 in
pitch BWG = 14
IDs = 29 in IDt = 0,834 in
Baffle (B) = 10.8 in L = 10 ft
ns = 1 Pt. = 1,25 in
Amount Baffle= 134 Nt = 376
Rd= 0.0033
4.3 Discussion
In every chemical industry involve heat transfer process. Heat transfer
occurs due to temperature difference between media with the system. Heat
exchanger or heat exchangers is an important tool to support the business
processes saving or energy efficiency or heat in a chemical process.
One of the criteria used to determine whether the heat exchanger is
designed to work well or not is through some parameters. Parameters - parameters
used in the redesign of a Heat Exchanger covers much value Rd (dirt factor) and
a decrease in pressure / pressure drop (ΔP). Price Rd not far beyond Rd minimal
price, because Rd which passes Rd minimal indicates that the sediment contained
in Heat Exchanger is already quite a lot.
The pressure drop (ΔP) which likely will lead to decreased driving force
each - each fluid, this will also lead to decreased performance in Heat Exchanger
for the pressure drop (ΔP) large amount of fluid flowing at the inlet shell and tube
will be much different with fluid flowing on shell and tube outlet.
a. Dirt factor (Rd)
Rd or fouling factor is a quantity that indicates the amount of
impurities deposited in Heat Exchanger. Usually this amount is proportional
to the time, the longer the Heat Exchanger is not in the clear, the greater the
amount of deposits of impurities. This is caused by the existence of which is

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1 – 30 January 2016
a problem in the shell and tube HE, ie the crust / dirt on the pipe so that the
heat transfer is no longer effective. The thicker the crust, the resistance to heat
transfer process increasingly large that the heat transfer coefficient becomes
small.
Based on calculations, it is known that the prices Rd (dirt factor) design
for HE-3 price equal to the price minimum Rd design. Price Rd minimum
design for 0003 hr ft2 °F / Btu while prices Rd design for HE-3 amounted to
0.0036 hr ft2 ° F / Btu.
b. Pressure drop (∆P )
The pressure drop in both the shell and tube must not exceed the
allowable pressure drop. Pressure in Heat Exchanger a driving force for fluid
flow in the shell or in the tube, if the pressure drop is greater than that
permitted. it will cause the flow rate of the mass (LBM / h) fluid inlet in the
shell and tube much different from the mass flow rate of outlets each - each
fluid. This will decreased the performance of the Heat Exchanger.
Based on calculations, for HE-3 can be seen that the pressure drop (ΔP)
in the shell of 0.415 psi still under price pressure drop (ΔP) design at 10 psi.
While the pressure drop (ΔP) in the tube for HE-3 is 0.164 psi value is still
below the value of pressure drop (ΔP) at 10 psi design.

REPORT
1 – 30 January 2016
CHAPTER V
CONCLUSION
5.1. Conclusion
Based on observations that have been made during the practical work in Cepu
Oil and Gas Training Center, obtained the following conclusion;
1. Value of dirt factor or fouling factor (Rd) from redesign HE-3 capacity 300 m3
is 0.0036 hr ft2 °F/Btu, while Rd HE-3 capacity 600 m3 is 0.0033 hr ft2 °F/Btu
2. Pressure drop (∆P) at redesign HE-3 capacity 300 m3 at tube is 0.164 psi and for
shell is 0.4154 psi, while redesign HE-3 capacity 600 m3 at tube is 0.1625 psi
and for shell is 0.2294 psi
3. For Re-Design HE capacity 600 m3, the ID of HE in the plant more large than
Re-Design, and it’s not standard if ID HE in the plant is 30.748 in, while Re-
Design HE get value standard is 29 in
4. From result of redesign HE-3 capacity 300 m3 get dimension :
 Type HE : HE 1-2 Shell and Tube, triangular pitch
 Lenght : 10 ft
 OD tube : 1 in
 BWG : 14
 Nt : 232
 Amount Baffle : 210
 B : 6.8 in
 Diameter shell : 23.25 in
While result of redesign HE-3 capacity 600 m3 get dimension :
 Type HE : HE 1-2 Shell and Tube, triangular pitch
 Lenght : 10 ft
 OD tube : 1 in
 BWG : 14
 Nt : 376
 Amount Baffle : 133

REPORT
1 – 30 January 2016
 B : 10.8 in
 Diameter shell : 23.25 in
5.2. Advise
Advice which we can pass on the factory as follows;
1. The need for the installation of temperature measuring devices and flow more
accurate so that changes in temperature, the flow can be known better and
precise
2. Quickly handle when the leakage of fluid either cold or hot, because it will
cause a reduction in flow rate, causing an increase in the value of Rd and also
can reduce the price of hot or cold viscosity of the fluid that will have an
impact on the increase in pressure (ΔP)
3. In order not to waste too much heat to the environment then the outer shell
are good insulators mounted
4. HE in the plant must be change because there is decreasing capacity from 600
m3 to 300 m3, to keep the optimal condition


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REPORT

Cepu Oil and Gas Training Center (PUSDIKLAT)

Chemical Engineering Yulira Kus Rendra 1

Chemical Engineering Yulira Kus Rendra 2

Chemical Engineering Yulira Kus Rendra 3

2.2. Type of Heat Exchanger

Chemical Engineering Yulira Kus Rendra 4

2.3. Component of Heat Exchanger

Figure 2.1 Layout Tube

Chemical Engineering Yulira Kus Rendra 5

Chemical Engineering Yulira Kus Rendra 6

a. Maintaining a long tube that is always between two tube sheet

Chemical Engineering Yulira Kus Rendra 7

 Sediment/ Suspended Solid / Fouling

Chemical Engineering Yulira Kus Rendra 8

Chemical Engineering Yulira Kus Rendra 9

3.1 COLLECTING DATA

Chemical Engineering Yulira Kus Rendra 10

t2= 213.80F t1= 131.80F

TUBE (Crude Oil)

Chemical Engineering Yulira Kus Rendra 11

4.2 Calculation to Redesign HE-3

Requirements that must be considered in the design of Heat Exchanger is;

WSolar = Vs 𝑥 SGs WCrude Oil = Vm 𝑥 SGm

156306 𝐿 1 hari 372000 𝐿 1 hari

Chemical Engineering Yulira Kus Rendra 12

3. Determine value q solar and Crude Oil

 Flow rate at cold fluid is Crude Oil

Chemical Engineering Yulira Kus Rendra 13

∆𝑇− ∆𝑡 183.96 °F− 199.62 °F

6. Determine factor correction real for LMTD (Ft)

Chemical Engineering Yulira Kus Rendra 14

At HE-3 ODtube 1 in, BWG=14, get

From table 9 Kern at 1 in OD tubes on 1.25 Triangular Pitch choosen :

(N + 1) = 30, so amount of baffle = (360 -1) =210

Chemical Engineering Yulira Kus Rendra 15

8. Calculate cross sectional area (a) at Shell and Tube

9. Calculate mass velocity (G)

Chemical Engineering Yulira Kus Rendra 16

10. Determine Reynold Number

11. Calculate value jH

jH = 24 (Based fig. 28, kern) L 10 ft

jH = 3.8 (Based fig. 24, kern)

Chemical Engineering Yulira Kus Rendra 17

fig. 4, kern) and 4, kern) and

13. Determine Coefficient Heat Transfer

14. Determine Temperature Wall Outside Tube (Tw)

Chemical Engineering Yulira Kus Rendra 18

15. Calculate Value Φ

16. Calculate Corrected Coefficient

ho = 86.9331x 0.9312 hio = 35.07476x 1.1839

17. Calculate Clean Overall (Uc)

Rd = 0.0036 hr ft2 °F/Btu

Chemical Engineering Yulira Kus Rendra 19

19. Calculate Pressure Drop

PT  Pt  Pr

20. Redesign HE-3

Chemical Engineering Yulira Kus Rendra 20

Chemical Engineering Yulira Kus Rendra 21

Chemical Engineering Yulira Kus Rendra 22

Chemical Engineering Yulira Kus Rendra 23

Chemical Engineering Yulira Kus Rendra 24

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