Technological Institute of the

WATER
PRE-HEATER
(PH-102)
 Technological Institute of the

EQUIPMENT DESIGN OF WATER PRE-HEATER

WATER PRE-HEATER SPECIFICATION SHEET
OPERATING DATA
Equipment Tag Number PH - 102
Operation Continuous
Operating Pressure 101.3 kPa
Type Shell and Tube
Configuration Horizontal
TECHNICAL DATA
Shell Tube
Fluid Circulating Steam Water
Materials of Construction Carbon Steel Carbon Steel
Type TEMA Type E Plain, seamless
Pass 1 2
TUBE LAYOUT
BWG 14
Pitch Type Triangular
1
Tube OD 1 in. TEMA std. 0.0381 m
2
Tube ID 0.0339 m
Tube Length 1.83 m
Tube Pitch 0.0476 m
Number of Tubes (Design) 16 tubes
Number of Tubes in Center Row 6 tubes
SHELL LAYOUT
Shell ID – 8 in. 0.203 m
Shell OD 0.207 m
Baffle Spacing 0.1016 m
Number of Baffles 18 baffles
Shell Cover Type Torispherical
NOZZLE DESIGN
Tube Nozzle Inside Diameter 1.38 in
Tube Nozzle Outside Diameter 1.66 in
Shell Nozzle Inside Diameter 1.94 in
Shell Nozzle Outside Diameter 2.38 in

DATA AND ASSUMPTIONS:

 Mass flow rate of water is 0.61537 kg/s.

 Mass flow rae of steam is 0.085797 kg/s.

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 24-hour operation for 7 days

 Shell Material Construction is Stainless Steel 304.
 Tube Material Construction is Stainless Steel 304.
 Operating Pressure is 1 atm.
 Shell Side Inlet Temperature = 104.54°C.
 Shell Side Outlet Temperature = 104.54°C.
 Tube Side Inlet Temperature = 30°C.
 Tube Side Outlet Temperature = 95°C.

From Overall Energy Balance:

Q=167.355 kW
kg
mass of steam required m s=0.0 85797
S
Shell Side: Steam
T 1=104.54 C

T 2=104.54 C

Tube Side: Water

t 1=30 C

t 2=95 C

Mean Temperature Difference:

∆ T lm=T s− ( t +t2 )
1 2

∆ T lm=104.54 ℃− ( 30℃ +2 90℃ )

∆ T lm=42.04 ℃

Dimensionless Temperature Ratio:

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T 1−T 2 104.54−104.54
R= = =0
t 2−t 1 95−30
t 2−t 1 95−30
S= = =0.8720
T 1−t 1 104.54−30

Correction Factor:
F t=F ( R , S ) =1

True Temperature Difference:

∆ T m=F t ∆ T lm

∆ T m=1 ( 42.04 )

∆ T m=42.04 K

Assume Overall Heat Transfer Coefficient:

W
U o , assumed =1710
m2 K
Heat Transfer Area:
Q
A=
U 0 ,assumed ∆T m

A=
( 167.355 kW ) ( 1000 W
1 kW )

(1710 mWK ) ( 42.04 K )

2

A=2.3280 m2

Surface area of a single tube:

a t=π ODt Lt

a t=π ( 0.0254 m ) (1.83 m )

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a t=0.1460 m 2

Number of Tubes:

nt = ( aA )( no . of shell1 passes )
t

2.3280 m2 1
nt = (
0.21904 m2 1 )( )
=15.9421

nt ≈ 16

Using TEMA Standard:

N t ≅ 16 tubes(accdg¿TEMA)
Shell inside diameter , ID s=8∈≈ 0.2032 m

Tube Bundle Diameter:

For triangular pitch,
K 1=0.249

n1 =2.207
1
N
Dbundle =OD t t
K1 ( ) n1

1
16
Dbundle =( 0.02032 ) ( 0.249 ) 2.207

Dbundle =0.1675 m

Number of Tubes in Center Row:

Db 0.1675m
N r ,c = = =5.2755
P t 0.03175
N r ,c ≈ 6 tubes

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Baffle spacing:
25 % baffle cut
B=0.5 ID s=0.5 ( 0.2032 m )

B=0.1016 m

Number of baffles:
Lt
=n B +1
B
Where:
Lt
=no . of ×the flow crosses the tubebundle
B
Lt 1.83
n B= −1= −1
B 0.1016
n B=17.0118 ≈ 18 baffles

Check:
B nB =( 0.1016 m )( 18 baffles )=1.8288 m<1.83 m(Tube Length)

Therefore, baffle spacing is acceptable

TUBE-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE

Tube-side mean temperature:

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T 1 +T 2 ( 30 ) +(395)
T= =
2 2
T =62.5 ℃

Table 5.53 Thermodynamic properties of air at tube-side mean temperature

Water
kg
Density 981.87
m3
kg
Viscosity 0.0000449
m∙ s
W
Thermal Conductivity 0.68045
m∙ K
kJ
Specific Heat Capacity 4.1841
kg ∙ K

Tube cross-sectional area:

π π
At ,c = ( IDt )2= ( 0.02118 m )2
4 4

At ,c =0.000352 m 2

Tube per pass:

Nt 16
nt , p = =
no . of tube passes 2
nt , p =8 tubes

Total flow area:

At ,total=nt , p At ,c =8 ( 0.000352m2 )

At ,total=0.002819m2

Tube-side mass velocity:

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kg
0.6154
mt s
Gt = =
A t ,total 0.002819 m2

kg
G t =218.3243
m2 s
Tube-side linear velocity:
kg
218.3243
G m2 s
ut = t =
ρt kg
981.87 3
m
m
ut =0.2224
s
Tube-side Reynolds number:
kg

ℜ=
Gt d e
=
( 97.5125
m2 s )
( 0.03388 m )

μt kg
0.0000449
m∙s
ℜ=102,998.3179

Tube-side Prandtl number:

kJ 1000 J kg
P=
cμ t
=
( 4.1841
t kgK
×
kJ )( 0.0000449
m∙ s )
r
k t
( 0.68045 mW∙ K )
Pr =0.2761

Length to diameter ratio:

Lt 1.83
=
ID s 0.2032
Lt
=9.0059
ID s

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Tube-side coefficient:
E=0.0225 exp ¿
E=0.021677

St =0.02237 ( 17,251.89−0.205 )( 1.6642−0.505 )

St=0.0038963

m kg kJ
(
hi =( 0.0038963 ) 0.099312
s )(
981.87 3 4.1841
m )(
kg ∙ K
¿) )
W
hi =3559.2657 `
m2 K

SHELL-SIDE HEAT TRANSFER COEFFICIENT: SINGLE PHASE

Shell-side mean temperature:
t 1 +t 2 104.54+ 104.54
t= =
2 2
t=104.54 ℃

Table 5.54 Thermodynamic properties of steam at shell-side mean temperature.

Steam
kg
Density 0.0705
m3
kg
Viscosity 1.24 x 10−5
m∙ s
W
Thermal Conductivity 0.0253
m∙ K
kJ
Specific Heat Capacity 2.0983
kgK

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Clearance between tubes:

C=Pt −ODt =0.03175 m−0.0254 m

C=0.006350 m
Cross flow area:
C IDs B
A s=
Pt

( 0.006350 m ) ( 0.2032 m) ( 0.1016 m )

A s=
0.03175 m

A s=0.004129 m 2

Shell-side mass velocity:

kg
ms
Gs = =
(
0.085797
s )
A s 0.004129 m2

kg
G s =20.7789
m2 ∙ s
Shell-side linear velocity:
kg
20.7789
Gs m2 ∙ s
u s= =
ρ kg
0.705 3
m
m
u s=29.4736
s

Shell-side equivalent diameter:

1.27 2
d e= ( P −0.785 OD2t )
OD t t

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1.27
d e= ( 0.031752−0.785 ( 0.0254 )2 )
0.0381 m
d e =0.0251 m

Shell-side Reynolds number:

kg

ℜ=
G s de
=
( 20.7789
m2 ∙ s )
( 0.0251m )

μ kg
0.0000124
m∙ s
ℜ=42028.1164
Shell-side Prandtl number:
kJ 1000 J kg
c μ
Pr = p =
(2.0983 kgK ×
kJ )(
0.0000124
m∙ s )
k
(0.0253 m∙WK )
Pr =1.028

Baffle cut: 25 % baffle cut

j n =3 x 10−3

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Assumed Heat Transfer Coefficient, ha

1
3
j n ℜ Pr k
h a ,S =
De

1
−3 3
( 3 x 10 ) ( 28018.80 ) (1.028 ) ( 0.0253 )
h a ,S =
0.0251 m

W
h a ,S =12838.0554 2
m −K

Viscosity Correction Factor

U
T W= (T −T t , mean ) +T t ,mean
ha , S S ,mean

1710
T W= ( 104.54−62.5 ) +62.5
12838.0554

T W =68.0996 ℃

μW =1.11 x 10−5 Pa−s

Shell-side coefficient:
1 0.14
hs d e μ
k ( )
= j n ℜ Pr 3
μw

Without viscosity correction term:

W
( 0.0253
mK )
) ( 42028.1164 ) 1.02842 W
1
1.24 x 10−5
0.14
h=s ( 3 x 10
0.0251 m
−3
( m∙ K )(
3
1.11 x 10−5 )

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W
h s=13038.6631
m2 K

Overall Heat Transfer Coefficient

Estimate:
W
tube wall material thermal conductivity , k w =45
m℃
W
outside dirt coefficient , hod =10,000
m2 ℃
W
inside dirt coefficient , hid =5,000
m2 ℃

Overall Heat Transfer Coefficient, U

OD t
1 1 1
OD t ln ( )
ID t ODt 1 ODt 1
= + +
U o hs hod 2 kw
+
[ ×
IDt hid
+
][ ×
ID t ht ]
1
=113038.6631
Uo

0.0254
1 1 1
( 0.0254 m ) ln ( 0.02118 ) + 0.0254 × 1 0.0254
Uo
=
13038.66
W
m2 K
+
10,000
W
m2 K
+
2 ( 45
W
m∙ K ) [ 0.02118
5,000 2
W
m K ][
+
0.02118
×

W
U o , calc =1242.6078
m2 K

Percent Error

%Error=0 %< |1242.617101−1710 × 100|<30 %

%Error=27.33 %

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Therefore, the assumed overall heat transfer coefficient is acceptable.

PERCENT OVERSURFACE
A− A c
% oversurface=15 % ≤ | Ac |
× 100 <50 %

Where:

A=HTA=2.3280 m 2
(Q)
Ac =
( U ) (∆ T M )

Ac =HTA based on calculated U o <¿

Ac =
(167.356 kW ) ( 1000W
1 kW )
W
( 1242.61
m2 K )
( 42.04 K )

Ac =3.2036 m2

% oversurface= |2.3280−3.2036
3.2036 |x 100
% oversurface=27.33 %

PERCENT OVERDESIGN
Design area ( N t =13)
A=π OD t Lt N t

A=π ( 0.01 83 m )( 1.83 ) ( 16 )

A=2.3365 m2
Required heat transfer area ( N t =14 )
Areqd =π OD t Lt N t

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¿ π (0.0183 m)(1.83)(16)

A=2.3365 m2
Calculating for percent overdesign

% overdesign= |2.3365−2.3365
2.3365 |×100
% overdesign=0 %
Therefore, the overdesign is acceptable.

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TUBE-SIDE PRESSURE DROP

L ρ u2t
∆ Pt =N p 8 j f
[ ( ) ]( )
IDt
+ 2.5
2

Estimate j f from Figure 12.30

j f =0.039
2
kg m
( )( )
]( )
981.87 3
0.2224
1.83 m m s
[
∆ Pt =2 8 ( 0.039 ) ( 0.2118)+2.5
2

∆ Pt =1430.03 Pa

∆ Pt =1.4303 kPa

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SHELL-SIDE PRESSURE DROP

ID s Lt ρ u2s
{ ( )( )( )( }
−0.14
μ
∆ P s= 8 j f
de B 2 μw )
Estimate j f
25 % baffle cut
j f =0.04

2
kg m

{ (
∆ P s= 8 ( 0.04 )
0. 2032 m
0.0 251 m )( 1.83 m
0.1016 m ) ( ( 0.705
m 3)(
29.4736

2
s )
)( 1.24 x 10−5
1.1 1 x 10−5
−0.14

) }
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∆ P s=14079.4355 Pa

∆ P s=14.079 kPa

EFFECTIVENESS OF HEAT EXCHANGER

For one shell pass and two tube passes:

0.5 −1
1+exp −( NTU ) ( 1+C 2r )
[ ]
{ 0.5
ε =2 1+C r + ( 1+C 2r ) ×
2 0.5
1−exp [ −( NTU ) ( 1+C ) ]
r
}
For steam:
kg kJ
(
C h=m h Cp h= 0.085797
s)(
2.0983
kgK )
kW
C h=0.18003 =C min
K

For water:
kg kJ
(
C c =m c Cp c = 0.6154
s)(
4.1841
kgK )
kW
C c =2.5748 =C max
K

Capacity ratio:
C min
Capacity Ratio ,C r =
C max
0.18003
C r=
2.5748
C r=0.06992

Inside depth of the head:

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0.5
ID ID
[( )(
d i=R c − Rc − s R c + s +2 R k
2 2 ) ]
Where:
Rc =ID s=203.2 mm

Rk =0.06 Rc =12.1920 mm
0.5
203.2 203.2
[(
d i=203.2− 203.2−
2 )(
203.2+
2 )
+ 2 ( 12.1920 )
]
d i=27.1544 mm

Effective exchanger length:

Leff =Lt +2 d i=1.83 m+ 2 ( 27.1544 m )

Leff =1.8843 m

Area effective:
Ae =π ODt L eff N t =π ( 0.0381m ) ( 1.8843 m) ( 16 )

Ae =2.4058 m2

Calculating for NTU:

U o , calc A e
NTU =
C min

NTU =
( 1242.61
m K)
( 2.4058 m )
2
2

( 0.18003 kWK × 1000 W

kW )
NTU =16.6055
Effectiveness:

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0.5 −1
1+exp [−( 16.6055 ) ( 1+0.069922 ) ]
{
ε =2 1+0.06992 ( 1+0.06992 ) × 2 0.5

1−exp [−( 16.6055 ) ( 1+0.069922 )

0.5
] }
ε =96.51 %

MECHANICAL DESIGN
Shell Tube
Stainless Steel, type Stainless Steel, type
Material of construction
304 304
Allowable stress (Design
1 44 MPa
stress)

Design pressure:
Take as 10 percent above operating pressure

P' =1.1 x 101.325 kPa

P' =111.46 kPa

Design temperature:
Take as 10 percent above operating temperature

T ' =1.1 ( 104.54 ℃ )

T ' =115 ℃

SHELL DESIGN
Shell thickness:
For a cylindrical shell, the minimum thickness required to resist internal
pressure can be determined from the equation below based on the maximum
allowable stress and corrected for welded joint efficiency:

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P' ID s
e=
2 Jf −P '
Where:
f =design stress
e=minimum thicknessrequired
J= joint factor , range ¿ 0.7−1.0
Calculating for shell thickness:

e=
( 0.11146 MPa )( 0.2032 m ) ( 10001 mmm )
2 ( 0.7 ) (1 4 4 MPa )−( 0.11146 MPa )
e=0.1124 mm

Add corrosion allowance taken as 2.0 mm:

e=0 .1124 mm+2.00 mm=2.1124 mm

Shell outside diameter:

OD s=ID s +2 e

OD s=203.2 mm+2.1124 (2)mm

OD s=2 07.4252 mm

COVER AND CHANNEL DESIGN

For the shell head design, a torispherical head is selected. According to
IS: 4503, the minimum thickness of the shell cover should be at least equal to
the thickness of the shell.

Shell cover thickness:

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The required thickness of a torispherical head can be determined from

the equation below.

P ' Rc C s
e sc =
2 fJ + P' ( C s−0.2 )

Where:
C s=stress concentration factor

Rc =crown radius

For torispherical head, stress concentration factor is given by:

R
C s=
1
4 ( √ )
3+ c
Rk

Where:
Rk =knuckle radius

Let:
Rc =ID s=203.2 mm

Rk =0.06 Rc =12.19 mm

For formed domed heads (no joints in the head), joint factor J=1.0

Calculating for stress concentration factor:

1 203.2
C s=
4 ( √
3+
12.19 )
C s=1.7706

Calculating for shell cover thickness:

( 0.11146 MPa )( 203.2 mm ) ( 1.7706 )
e sc =
2 ( 124 MPa )( 1 ) + ( 0.1146 MPa )( 1.7706−0.2 )
e sc =0 .1392 mm

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Add corrosion allowance taken as 2.0 mm:

e sh =0. 1392 mm+2.00 mm=2. 1392 mm

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Channel cover thickness:

The channel cover material is the same as the shell material. The outside
diameter of the channel shall be the same as that of the shell. The effective
channel cover thickness can be determined from the equation below.
'
d √C 1 P
t cc =
10 f
Where:
t=thickness of the channel cover [mm]
d=diameter of the cover [ mm ] usually same as the outside shell diameter
C 1=factor equal ¿ 0.3 for ring type gasket

kgf
P' =design pressure[ ]
cm2
kgf
f =design stress [ ]
mm2

Calculating for channel cover thickness:

207.425 mm √ 0.3 ( 1.13655 )

t cc =
10 14.6840
t cc =0.8248 mm

Add corrosion allowance taken as 3.0 mm:

t cc =0.8248+3.00 mm

t cc =3.8248 mm

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Tube sheet thickness:

The tube sheet thickness is calculated based on the bending and
considering the design pressure only. The material is the same as the shell
material. The minimum tube sheet thickness to resist bending can be
determined from the equation below.
F Gp P
t ts =
3 kf√
For the stationary tube sheet in u-tube type:
F=1
G p=ID s

Mean ligament efficiency:

0.907
k =1−
Pt 2
( )
OD t

0.907
k =1− 2
0.0 3175
( 0.0 254 )
k =0.41952
Calculating for tube sheet thickness:

( 1 ) ( 203.2 mm ) ( 0.11146 MPa )

t ts =
3 √
( 0.41952 ) ( 1 4 4 MPa )
t ts =2.9094 mm`

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NOZZLE DESIGN

General Guidelines

 For inlet fluids (liquids or gas): ρv2 ≤ 1000 kg/m-s2

 For outlet gas: ρv2 ≤ 3600 kg/m-s2
 For outlet liquids: v = 1 m/s

Shell Nozzle

ρ v2 1000
v sh=
√ √ρs
=
0.705 kg/m3

m
v sh=37.6627
s

ms 0.08579
A sh= =
ρ s v s (0.705 kg /m 3)(37.6627)

A sh=0.00323 m2

4 A sh 4 ( 0.00323 m 2 )
d sh=
√ √π
=
π

d sh=0.06414 m≈ 2.5253∈¿

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Table 5. 1 Nominal Pipe Size for Nozzle Design

Nominal Pipe Size 2 ½ in

Schedule Number 10S
Inside Diameter 2.635 in
Outside Diameter 2.875 in
Wall thickness 0.12 in
Area 1.039 in2

Tube Nozzle

ρ v2 1000
√ √
v tu=
ρs
=
981.87 kg/m 3

m
v tu=1.0 0 9 2
s

mw 0.615368 kg/s
Atu = =
ρw v w ( 981.87 kg/m3 )( 1.02389m/ s)

Atu =0.0006 32 m 2

4 Atu 4 ( 0.0006 32 m 2 )
√ √
d tu =
π
=
π

d tu =0.028 4 m≈ 1.1 17∈¿

Table 5. 2 Nominal Pipe Size for Nozzle Design

Nominal Pipe Size 1.25 in

Schedule Number 40,40ST
Inside Diameter 1.38 in

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Outside Diameter 1.66 in

Wall thickness 0.14 in
Area 0.668 in2

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