Heat exchanger engineering techniques : process, air conditioning, and electronic systems : a treatise on heat exchanger installations that did not meet performance

335 Pages·2003·10.37 MB·English

by  Michael J

HEAT EXCHANGER
ENGINEERING
TECHNIQUES
PROCESS, AIR CONDITIONING,
AND ELECTRONIC SYSTEMS
A Treatise on Heat Exchanger Installations
That Did Not Meet Performance
Michael J. Nee
ASME Press
The American Society of
Mechanical Engineers
New York, New York
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Copyright © 2003
The American Society of Mechanical Engineers
Three Park Ave., New York, NY 10016
Library of Congress Cataloging-in-Publication Data
Nee, Michael J., 1924-
Heat exchanger engineering techniques: process, air conditioning, and
electronic systems/Michael J. Nee
p. cm.
Includes bibliographical references and index.
ISBN 0-7918-0167-5
1. Heat exchangers. 2. Cooling. 3. Industrial buildings—Air conditioning.
I. Title.
TH7684.F2N44 2003
621.402’5—dc21 2003040423
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To My Wife, Virginia, and to Our Children,
Michael, Mary, Rita, and Tim
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Engineering
It is a great profession. There is the fascination of watching a figment of the
imagination emerge through the aid of science to a plan on paper. Then it
moves to realization in stone or metal or energy. Then it brings jobs and homes
to men. Then it elevates the standards of living and adds to the comforts of life.
That is the engineer’s high privilege.
The great liability of the engineer compared to men of other professions is
that his works are out in the open where all can see them. His acts, step by step,
are in hard substance. He cannot bury his mistakes in the grave like the doc-
tors. He cannot argue them into thin air or blame the judge like the lawyers. He
cannot, like the architects, cover his failures with trees and vines. He cannot,
like the politicians, screen his shortcomings by blaming his opponents and
hope the people will forget. The engineer simply cannot deny he did it. If his
works do not work, he is damned. . . .
On the other hand, unlike the doctor his is not a life among the weak. Unlike
the soldier, destruction is not his purpose. Unlike the lawyer, quarrels are not
his daily bread. To the engineer falls the job of clothing the bare bones of science
with life, comfort, and hope. No doubt as years go by the people forget which
engineer did it, if they ever knew. Or some politician puts his name on it. Or
they credit it to some promoter who used other people’s money. . . . But the engi-
neer himself looks back at the unending stream of goodness which flows from
his successes with satisfactions that few professions may know. And the verdict
of his fellow professionals is all the accolade he wants.
Herbert Hoover
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Contents
Preface xv
Acknowledgment xix
List of Figures xxi
List of Tables xxv
Part 1 Process Exchangers 1
Chapter 1 Personnel and Requirements 3
1.1 The Selection of Exchangers..................................................................3
1.2 Personnel Involved in Identifying Requirements..................................4
1.3 Requirements by Application...............................................................14
1.4 Problems Due to a Missing Requirement............................................16
1.5 Requirements That Define What Is and What Is Not Wanted...........21
1.6 Requirements for Fluid Properties......................................................21
1.7 Summary of Problem Areas.................................................................22
1.8 Cleaning and Fouling............................................................................23
1.9 Contract Requirements between Seller and Buyer.............................23
Chapter 2 Considerations before Finalizing the Selection 25
2.1 Considerations Before Finalizing the Selection..................................26
2.2 Effect of Tube Length and Mechanical Cleaning upon Cost..............26
2.3 Parallel Flow..........................................................................................28
2.4 Tube-Side Considerations in Selecting an Exchanger........................29
Chapter 3 Considerations in Selecting Shell-and-Tube
Exchangers 45
3.1 General..................................................................................................45
3.2 Tube Sizes and Patterns........................................................................45
3.3 Shell-Side Designation and Nomenclature.........................................47
3.4 Shell Types.............................................................................................50
3.5 Front-End Types....................................................................................54
3.6 Summary of Shell-and-Tube Designs and Their Limitations.............58
Chapter 4 Air Coolers 59
4.1 Beginning the Process of Selecting an Air Cooler...............................63
4.2 Some Governing Conditions................................................................63
4.3 Structural Considerations....................................................................66
vii
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viii • Contents
4.4 Forced- versus Induced-Draft Air Coolers...........................................69
4.5 Process Heat Transfer Coil or Section.................................................71
4.6 Plate-Fin and Spiral-Fin Extended-Surface Exchangers....................77
4.7 Duct Coolers..........................................................................................79
4.8 Selecting Several Air Coolers to Dissipate Heat..................................79
4.9 Calculating Surface and Airflow Area for Fin Coils............................81
Chapter 5 Extended-Surface Metallurgy 87
5.1 Selecting Aluminum or Copper Fins...................................................87
5.2 Fins of Materials Other Than Copper or Aluminum..........................89
5.3 Lowfin Tubes.........................................................................................92
5.4 Some Rules of Thumb for Finned Surfaces........................................92
Chapter 6 Air Cooler Fans or Blowers 95
6.1 Fan Coverage and Bundle Geometry...................................................95
6.2 Fans and Blowers..................................................................................98
6.3 Fan Drives.............................................................................................99
Chapter 7 Exchangers with Longitudinal-Fin Tubes 103
7.1 Double-Pipe Exchangers....................................................................103
7.2 Tank Heaters.......................................................................................105
7.3 Line Heaters........................................................................................106
7.4 Overall Heat Transfer Rate Using Longitudinal-Fin Tubes..............107
Chapter 8 Plate Exchangers 109
8.1 Construction Features........................................................................109
8.2 Plate Exchangers versus Shell-and-Tube and Double-Pipe
Exchangers..........................................................................................109
8.3 Advantages and Disadvantages of Plate Exchangers........................114
8.4 Planning Ahead...................................................................................115
8.5 Cost Observation.................................................................................116
8.6 A Seasonal Application.......................................................................116
Chapter 9 Comparing Exchanger Types 119
9.1 Air Cooler Header Limits...................................................................119
9.2 Limitations in the Selection of Finned Surface................................120
Chapter 10 Fouling Factor Considerations 123
10.1 Plant Conditions...............................................................................123
10.2 Fouling Effect on Various Exchanger Designs................................125
10.3 Dealing with the Consequences ......................................................130
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Contents • ix
10.4 Ways of Minimizing the Effect of Fouling......................................130
10.5 Accounting for Fouling When Selecting an Exchanger..................131
Chapter 11 Manifolds and Headers 133
11.1 Selecting Manifolds..........................................................................133
11.2 Air Cooler Headers and Their Limitations......................................135
11.3 Header Nozzle Locations and Quarter Points.................................136
11.4 Lube Oil Cooler Header Design.......................................................137
11.5 Four Liquid Coolers in Parallel........................................................138
Chapter 12 Freezing 141
12.1 Antifreeze..........................................................................................141
12.2 Draining.............................................................................................142
12.3 Heating Air or Water.........................................................................142
12.4 Air Recirculation in Duct Systems...................................................142
12.5 Electric Heaters.................................................................................143
12.6 Hot Water and Steam Coils..............................................................144
12.7 Other Causes of Freezing, and Other Precautions..........................144
Chapter 13 The Iterative Process of Exchanger Selection 145
13.1 Shell-and-Tube Units........................................................................147
13.2 Air Coolers.........................................................................................149
13.3 Double-Pipe Exchangers..................................................................152
13.4 Plate Exchangers...............................................................................155
Chapter 14 Techniques to Reduce the Size of an Exchanger 157
14.1 Cooling with Hydrogen Gas.............................................................157
14.2 Lowfins..............................................................................................158
14.3 Internally and Externally Finned Tubes..........................................159
14.4 Turbulators........................................................................................161
14.5 Automatic Brush Cleaners................................................................164
14.6 Small-Diameter Tubes......................................................................166
14.7 Advantages of Plate Exchangers over Shell-and-Tube Units..........166
14.8 Designs That Use Fewer Finned Tubes per Layer
and More Layers...............................................................................166
Chapter 15 Techniques to Reduce Exchanger or System Cost 169
15.1 Quantity of Refrigerant in System...................................................169
15.2 Case Study: Quench Oil Cooler........................................................170
15.3 Air-Cooled Furfural Cooler Selection..............................................172
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x • Contents
15.4 Code and Noncode Units..................................................................173
15.5 Tubing................................................................................................175
15.6 Shop Assembly..................................................................................176
15.7 Rapid Delivery...................................................................................177
15.8 Energy................................................................................................178
15.9 Material and Construction Considerations.....................................178
Chapter 16 Adding Surface While Minimizing Downtime 183
16.1 Add More Plates in Plate Exchangers..............................................183
16.2 Change Fin Material.........................................................................183
16.3 Add a Precooler in the Makeup Air Line.........................................184
16.4 Add Double-Pipe Units to a Bank of Exchangers............................185
16.5 Replace Bundles with Smaller-Diameter or Lowfin Tubes.............185
16.6 Air Coolers.........................................................................................186
16.7 Insulation..........................................................................................186
Chapter 17 Features That Should Make Selections
Unacceptable 187
17.1 Face Velocity (Coil) and Air Velocity (Duct)....................................187
17.2 Water Velocity Limits.......................................................................188
17.3 Noise..................................................................................................189
17.4 Stacking Units...................................................................................190
17.5 Conserving Energy............................................................................191
17.6 Dimensional Limits..........................................................................193
17.7 Liquid Flow across Fins...................................................................193
Chapter 18 The Significance of Metal Temperature 195
18.1 Significance of Tube-Wall Temperature in Sizing an Exchanger....195
18.2 Condenser Driving Force................................................................198
18.3 Heating with Desuperheated Steam..............................................198
18.4 Bulk Viscosity and Tube-Wall Viscosity.........................................199
18.5 Changing Metallurgy.......................................................................199
18.6 Subcooling.......................................................................................199
18.7 Product Temperature Too High......................................................199
18.8 Reboilers..........................................................................................201
18.9 Thermal Expansion in U-Tube Exchangers...................................201
18.10 Radiant Energy Affecting a Roof or Canopy.................................201
18.11 Tank Shell........................................................................................202
18.12 Cables and Circuit Breakers...........................................................202
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