As a standard, johnston builds these vessels with control connections on both sides. Practical thermal design of shellandtube heat exchangers. The furnaceflame volume can either be inside or external to the shell that contains the water. Guide for planning, selecting and designing of shell and tube exchangers. The upper steam capacity of fire tube boilers is about 20,000 ibmhr, and the peak pressure. The optimum thermal design of a shell and tube heat exchanger involves the consideration of. As the time has passed, more efficient types of boilers have replaced the old and inefficient ones. This is the third edition of a standard text book which has beem. Since, in this example, the gases cross through the case two times before exiting. The benefits of the water tube steam boiler design include the following. Because the boiler is hotter than its environment, some heat will be transferred to the surroundings. Jekayinfa simeon olatayo inaugural lecture series 22. Shell boilers may be defined as those boilers in which the heat transfer surfaces are all contained within a steel shell.
This book provides readers with a handson, illustrated guide to the design and. A practical guide for planning, selecting and designing of shell and tube exchangers takes users on a stepbystep guide to the design of heat exchangers in daily practice, showing how to determine the effective driving temperature difference for heat transfer. The shell and tube exchanger basically consists of a number of connected components, some of which are also used in the construction of other types of exchangers. Jun 01, 2017 i already prepared simple presentation about design of shell and tube heat exchanger. The different types of boilers find their use in different applications. The pressurized components of the shell and tube exchanger are designed to be in accordance with a pressure vessel design code such as asme viii 1993 or bs5500 1994. The mechanical design of a shell and tube heat exchanger provides information on items such as shell thickness, flange thickness, etc. This book is intended to help theoreticians for conceptual development of shell and tube heat exchanger. I am in my final year and the title of my design project is production of hydrogen using steam reforming. The boiler heats up or evaporates the water inside it, which is then transported to the consumers via pipe systems. Boiler basics design and application differences youtube. There are at least six consideration to decide if hot fluid or cold fluid is located in shell side or tube side.
Comparative analysis of finned tube and bared tube type. The figure below equations shows a standard three pass fire tube steam boiler system used as a template for our engineering teams design. Materials and construction shell and tube heat exchangers. Design of shell and tube heat exchanger layout design. The industrial watertube boiler typically produces steam or hot water primarily for industrial process applications, and is used less frequently for heating applications. Water tube design boilers are quite fit for applications needing large amounts of steam, such as industrial process purposes, and are used less often for heating purposes. This type of boiler has developed as a cross between a conventional shellandtube heat exchanger and a firetube boiler. A sound structural design that has been properly veri. This video provides a walkthrough for a sample design analysis homework problem for calculating the required area of a heat exchanger. The tubes may be straight or bent in the shape of a u, called utubes. The tubes may be straight or bent in the shape of a u, called u tubes. These are calculated using a pressure vessel design code such as the boiler and pressure vessel code from asme american society of mechanical engineers and the british master pressure vessel standard, bs 5500. The benefits of the fire tube boiler design include the following.
The tube sheet configuration in a multipass shell and tube design must have provisions for the pass ribs, requiring either removal of tubes to allow a low cost straight pass rib or alternately a pass rib with curves around the tubes adding cost to the manufacture. Air pre heaters primary objective is to extract the waste heat from the flue gases leaving the boiler. The design marked a transitional stage in boiler development, between the early haystack boilers and the later multitube firetube boilers. These firetube boilers could weigh up to 200,000lbs and reach speeds of 100mph. Number of generating bank tubes entering steam drum for ligament efficiency. Basesapplication of heat exchanger mechanical design rules. This type of boiler has developed as a cross between a conventional shell and tube heat exchanger and a firetube boiler. Principles of finnedtube heat exchanger design for enhanced heat transfer 2nd edition by dipl.
Large steam users are better suited for the watertube design. The optimum thermal design of a shell and tube heat exchanger involves the consideration of many interacting design parameters which can be summarised as follows. This uptodate reference covers the thermal design, operation and maintenance of the three major components in industrial heating and air conditioning systems including fossil fuelfired boilers, waste heat boilers and air conditioning evaporators. The simple boiler design and the full accessibility to the fire tubes, without. It may be of a two, three or four pass arrangement depicted by the number of tube passes within one common shell. Setting shell side and tube side pressure drop design limits. Selection of heat exchanger tema layout and number of passes. In case of hot water the transport energy is generated by. I am designing a waste heat boiler and i need information on how to start the design. Calculate the required heat transfer area based on values needed.
Industrial boiler systems can cope with much higher pressures than pressure cookers. Water tube boilers require less weight of metal for a given size. A reasonably wellinsulated shell or water tube boiler of 5 mw or more will lose between 0. Practical boiler opertaional, marine boilers, boiler operation and many more. E1mnl032a design and rating of shell and tube heat. Welcome to boiler and mechanical power digital library and training videos library. The maximum allowable working pressure mawp is 580 psi gauge.
Here is an example of a 12 1 shell pass and 2 tube passes heat exchanger. Design of shell and tube heat exchanger miss rifka. A reasonably wellinsulated shell or watertube boiler of 5 mw or more will lose between 0. This book covers the topics such as components of sthe, classification, data needed for the design,tube side design, shell side design, tube layout, baffles, channel design, tie rod and spacers. The code dictates the materials, processes and design of the pressure vessel. Thermal design of shell and tube heat exchangers bill watson on. Shell and tube configuration that heats the saturated steam coming from the. Karl ponweiser institute for thermodynamics and energy conversion vienna university of technology vienna, austria published by wseas press. Comparative analysis of finned tube and bared tube type shell. Principles of finned tube heat exchanger design for enhanced heat transfer 2nd edition by dipl. Firetube boiler 1800 the fire tube boiler, the oldest design, is made so the products of combustion pass through tubes surrounded by water in a shell. The water is inside the sections and the fire is outside the sections.
The minimum capacity of a water tube boiler is usually around 5 tph. Heat exchanger design handbook mechanical engineering. The cast iron sectional boiler is neither fire tube nor water tube though it has some operating characteristics of a water tube boiler. Finned tubes are now widely used in industrial shell and tube units used as boiler, economizers, in water heaters. Mar 12, 2015 boiler basics design and application differences july 2014. Except for some designs of feedwater preheaters where they have segmented baffles on the shellside and zigzag flow of the vapor, the shell is generally a tema. The best gauge of which design to consider can be found in the duty in which the boiler is to perform. I can advice you one thing that if you really want to increase your knowledge in practical and theoretical then try to use internet as much as. For the length scale, the tube outside diameter is employed. He has written a number of books on piping design, heat exchanger design.
Fire tube boilers also referred to as smoke tube boilers, shell boilers, package boilers multiple gas paths 2, 3 and 4 pass internal furnace or fire box as the 1st pass dry back or wet back design single fuel or dual fuel design little or no steam separation equipment. Pdf this paper presents the design of a laboratory firetube steam boiler for eventual construction and use. Books covers many topics like power plants, water treatment, steam turbines, health and safety, mechanical and electrical technology. I found it extremely useful as a design reference guide for industry professionals or course text book for engineering students. When cleaverbrooks or any other boiler manufacturer build a boiler, the pressure vessel must be built in accordance with asme\. In lees loss prevention in the process industries fourth edition, 2012. May 10, 2014 this video provides a walkthrough for a sample design analysis homework problem for calculating the required area of a heat exchanger. Calculate the minimum required wall thickness of a water tube boiler 2. These are some exchanger parts are important for the overall design of the exchanger shell and tube heat exchanger types.
Damaged or poorly installed insulation will greatly increase the potential heat losses. Specification of tube parameters size, layout, pitch. Due to their effectiveness and reliability, fire tube, or shell, boilers are fit for steamintensive industries and continuous or batch process. A practical guide for planning, selecting and designing of shell and tube. Shell boilers may also be referred to as fire tube or smoke tube boilers because the products of combustion pass through the boiler tubes, which in turn transfer heat to the surrounding boiler water. Typically, the ends of each tube are connected to plenums sometimes called water boxes through holes in tubesheets.
He is the current chairman of the asme subgroup on heat transfer equipment and a member of the boiler and pressure vessel committee and various other asme code committees. A shell or flued boiler is an early and relatively simple form of boiler used to make steam, usually for the purpose of driving a steam engine. Boiler evolution 4 steam locomotive cutaway furnace convection tubes. Fluid with higher corrosion tendency is allocated at tube side.
Design of shell and tube exchangers is commonly governed by the standards created by tema tubular exchangers manufacturers association. How an industrial boiler system works the heart of an industrial boiler system is a hot water or steam boiler operated with a certain kind of fuel. I usually calculate for both shell side and tube side just to ensure that the duty is similar. Boiler types and classifications wiki odesie by tech. May 28, 2017 this figure shows you general stepbystep method of design of shell and tube heat exchanger design of shell and tube heat exchanger. In all three types, the frontend head is stationary while the rearend head can be either stationary or floating see fig. Process heat recovery boilers, or waste heat boilers, are widely used, particularly on ethylene and ammonia plants and on sulfuric acid and nitric acid plants. Define the duty q from mass flow rate, inlet temperature, outlet temperature, and heat capacity. I already prepared simple presentation about design of shell and tube heat exchanger. Accessible in sizes far greater than a fire tube boiler design, up to some million pounds per hour. Looking at the contents and title, the author has made efforts to cover all aspects of heat exchanger design related to concepts, materials, geometry, fabrication, quality control and maintenance. The boiler design can also be identified by the shape of the tube configuration, with the common types being called a, o, and d style boilers. Basesapplication of heat exchanger mechanical design. Shell and tubesaturated steam boilers of the current packaged form have been manufactured since before the second world.
They will also calculate the number of tubes needed for a shell and tube heat exchanger and to calculate the pipe length needed for a double pipe heat exchanger. Shell and tube heat exchanger design by chemcad rating. Small combustion space and high heat release rate resulting in faster evaporation. This figure shows you general stepbystep method of design of shell and tube heat exchanger design of shell and tube heat exchanger. Waste heat boiler an overview sciencedirect topics. Boiler basics design and application differences july 2014. Comparative analysis of finned tube and bared tube type shell and tube heat exchanger. This type of heat exchanger consists of a set of tubes in a container called a shell. Asme code american society of mechanical engineering section i high pressure steam boilers above 15 psi. There can be many variations on the shell and tube design. Shell and tube configurations with up to 4 passes are the most common, however specialty designs do allow 20 or more crossings. Selecting the right boiler type for the application.
The design marked a transitional stage in boiler development, between the early haystack boilers and the later multi tube fire tube boilers. This chapter commences with an introduction to the fundamentals of boiler operation and outlining what exactly happens in a boiler. Heat exchanger calculations and design with excel spreadsheet. Boiler tubes thickness pressure equation and calculator. Our engineering team designed a threepass fire tube steam boiler with a capacity of 5000 kg of steam per hour and a operating pressure of 10 bar. Due to their effectiveness and reliability, firetube, or shell, boilers are fit for steamintensive industries and continuous or batch process. Process fluid assignments to shell side or tube side. A boiler is a closed vessel in which water is heated, steam is. Asme section i boiler tubes up to and including 5 inches o. Tube sheets cut and drilled 15 shell welding tube sheet cuttingdrilling. How shell and tube heat exchangers work engineering. Boiler design is the process of designing boilers used for various purposes. I want to design a shell and tube heat exchanger for steam. The boiler is of a wet back design with a fully submerged combustion chamber and firing tube.
There is a flame tube 1st pass in this pressure vessel. Gabriel aurioles is currently technology director for aspen technology, and has over 35 years of experience in the design of shell and tube heat exchangers and pressure vessels. Its original function was to cool high temperature process gas and, as a byproduct, to generate low pressure steam. Fire tube boilers of smaller size are vertical and those of larger size are horizontal. The shell and tube type heat exchanger is a nonfired pressure system consisting of two different. This is the first such practical book on sthe thermal design in the market. Air preheaters consist of a shell where tubes are arranged in a square or triangular pitch and are welded to a tube plate. Download the excel spreadsheet templates in this article to make preliminary heat exchanger design calculations. Most shellandtube heat exchangers have multiple passes to enhance the heat transfer. Steam boiler technology ebook is the main course book for the course on steam. Selection of heat transfer models and fouling coefficients for shell side and tube side.