Fluid allocations in shell

and tube heat exchangers

Chemklub India Pvt Ltd
• Fluid allocation in shell and tube heat exchangers is a key decision during the design of the exchanger to
ensure the achievement of the required thermal duty with optimized cost and satisfactory in-service
reliability. The selection of the correct side for each fluid depends on many interacting factors, some
related to the thermal design and some others related to the mechanical design and future
considerations of inspection and integrity monitoring of the exchanger.

• The best choice of routing can only be decided after designing both options in many cases. In some cases,
the selected side for each fluid is a tradeoff decision as there might be no one single selection which
satisfies all the required factors, and some may conflict with
others. Hence, understanding the effect of each parameter and the main features of each heat exchanger
type is very important to help in selecting the right optimized design.

• In addition, each of the exchanger types (fixed tube sheet, floating head tube sheet, or U tube heat
exchanger) has its own characteristics, which will be preferred for specific fluid applications over other
types.
 Main factors affecting fluid allocation:
• Allowable pressure drop: Flow areas in the shell side is higher than that of the tube side and flow
resistance and associated pressure drop will be lower. Fluids, of which pressure drop should be low to
satisfy the limiting operating conditions in the plant, should be allocated in the shell side.

• Fluid operating pressure and temperature: It is preferred to have the higher pressure fluid in the tube
side of the exchanger rather than the shell side, as the thickness of the pressure part is proportional with
its diameter. An example for that is the equation of the thickness required for the cylindrical part under
internal pressure (t=PR/SE-0.6P)where ‘t’ is the required thickness and ‘R’ is internal radius and ‘S’ is
the material allowable stress. A thick shell will impact the cost, foundation design, and might impact the
fabric ability of the shell (welding, forming and inspection requirements). In some cases, routing the
higher-pressure fluid through the shell may produce a cheaper unit, particularly if it reduces the
exchanger diameter and it is made of carbon steel.

• The impact of temperature is sometimes similar as, at high temperature, the material strength is
reduced and thus results in the allowable stress value (‘S’ in the equation). That will result in higher
calculated thickness which is preferred in the tube side.

• While allocating the higher pressure fluid in the tube side it is worth considering the 10/13 rule
during the de-termination of the shell side design pressure, if possible. Sometimes a minor
increase in shell side design pressure can achieve the 10/13 rule explained in the box text.
• Fluid viscosity: For highly viscous fluids, turbulent flow can be obtained easier at the shell side due to
the effect of baffles in changes of flow direction. It is preferred to pass higher viscous fluids in shell side.

• Viscous fluids also tend to have a higher pressure drop which supports routing them to the shell side to
minimize the pressure drop.

• Fluid heat transfer rate: Fluid with low heat transfer coefficients is preferred to be located in the shell
side as it can be more flexible to enhance the heat transfer by changing the flow patterns using the
baffles as the heat transfer is much higher for turbulence flow. If that fluid is located in tube side, then a
higher number of tube passes can be used for the velocity and flow turbulence.

• Fluid phases (one phase or two phases): Fluids which undergo phase changes should be located in the
shell side. Here, a large flow area can be used to accommodate vapor flow without increasing the
pressure drop. Whereas the flow which is condensed during the heat transfer is usually located in the
tube side.
• Dirty Fluids: Dirty fluids and fluids that contain suspended solids are better to be located in the tube side as it
is much easier to clean than the shell side. In case dirty fluids need to be located in the shell side due to other
considerations, it is preferred to use square tube pitch instead of a triangular pitch (despite lower heat transfer)
in order to facilitate cleaning the tube bundle from the shell side. Table 1 summarizes the main features of each
of each tube pitch.

• Fluid corrosivity: The effect of corrosion on selecting the ideal exchanger side for each fluid is difficult to
conclude however, as a general rule, it is usual to route the more expensive material in the tube side. In some
cases, if the fluid is not at high pressure and the switch reduces the shell diameter, it may provide a cheaper
solution. When the shell side fluid is prone to cracking, fixed tubesheet exchangers should be avoided and all
internal welds should be accessible for inspection. In addition, if a fluid has tendency to cause crevice corrosion
it is better to be routed in the tube side to avoid crevice corrosion between tube and tubesheet at the backside of
the tubesheet.

• Cooling water: Low velocities can promote increased corrosion. There must be sufficient velocity to main-tain
any particulate in suspension as it travels through the heat exchanger. Velocities below about 3 fps (1 m/s) are
likely to result in fouling, sedimentation, and increased corrosion in fresh and brackish water systems.
Accelerated corrosion can also result from dead spots or stagnant areas if cooling water used on the shell side of
heat exchangers rather than the preferred tube side. Velocity limits depend on the tube material and water
quality. With very few exceptions, cooling water should be on the tube side to minimize stagnant areas. On the
other hand, high water velocity can increase the corrosion by erosion corrosion mechanism and also by allowing
more oxygen to be carried to cathodic sites increasing the cathodic reaction rate. Hence, both very high and very
low water velocities should be avoided.
Main features of shell and tube for selection of
fluid allocation
• Fixed tubesheet heat exchanger: A fixed tubesheet heat exchanger has straight tubes that are secured
at both ends to tubesheets welded to the shell barrel. The principal advantage of the fixed tubesheet
construction is its low cost (as expansion joint is not required) because of its simple construction.The
outsides of the tubes cannot be cleaned mechanically (but can be chemically cleaned). Thus, its
application is limited to clean services on the shell side. Shell internal and tube bundle external surface
cannot be inspected.

• U tube heat exchanger: The tubes of a U tube heat exchanger are bent in the shape of a U and there is
only one tubesheet.In a U tube heat exchanger one end is free and the bundle can expand or contract in
response to stress differentials. In addition, the outsides of the tubes can be cleaned, as the tube bundle
can be removed. The main disadvantage of the U tube construction is that the insides of the tubes cannot
be cleaned effectively, since the U bends would require flexible end drill shafts for cleaning. Thus, U tube
heat exchangers should not be used for services with a dirty fluid inside the tubes.

• Another limitation is the inspection of the U bend area; most of the commercially available inspection
techniques could not pass through the bend areas unless using smaller probe Fill Factor (FF) and hence
less accuracy in the inspection results. A large fill factor (e.g. 85%) is desirable for optimal NDE (Non
Destructive Examination) performance. Compared to fixed tubesheet the cost will be in the same range;
although it will save the cost of the second tubesheet, it will also have the added cost for the bending of
the tubes and in many cases the stress relief heat treatment required for the U bend area. In addition, a
relative larger shell diameter due to the minimum U bend radius limitation increases cost as well.
Floating head heat exchanger: A floating head heat exchanger is the most versatile type of shell
and tube heat exchanger, and also the highest in cost. In this design, one tubesheet is fixed
relative to the shell, and the other is free to float within the shell.This permits free expansion of
the tube bundle, as well as cleaning of both the insides and outsides of the tubes.

Floating head shell and tube heat exchangers can be used for services where both the shell side
and the tube side fluids are dirty, making this the standard construction type used in dirty
services, such as in petroleum refineries.
Guidance for selecting TEMA type based on whether fluid is clean or
dirty.