Given Data
Crude Oil
Lube Oil
Nomenclature
mass flow rate of (hf)
mass flow rate of (cf)
inlet temperature of (cf)
outlet temperature of (cf)
Temperature Range of (cf)
inlet temperature of (hf)
outlet temperature of (hf)
Temperature Range of (hf)
Dirt Factor of inside scale based on inner surface
Dirt Factor of outside scale based on outer surface
Allowable Pressure drop
Length of 1 leg of hairpin
Length of per hairpin
NPS for outer pipe
NPS for Inner pipe
Average or mean Temperature of (cf)
Average or mean Temperature of (hf)
No.of Hairpins?
Arrangement of Heat Exchangers?
For Counter Current Flow
Hot terminal end temperature difference
Cold terminal end temperature difference
From given NPS of inner and outerpipe note Inner and Outer Diameters of both pipies
Reference PHT by Kern 1st Edn. Pg844
Flow Channel
Inner Pipe
Outer Pipe
Equivalent Diameter of Annulus fot H.T Calculations
Flow Area (Af)
Equivalent Diameter of Annulus fot Pressure Drop Calculations
Minor Check (De/De')
For H.T Calculations Dfc (Diameter of flow channel)
Dimensionless Ratio or (LHP/Dfc) ratio (x)
Correction factor for end effects Ψ=1+x^(-2/3)
Now In this problem we don't have imperical correlations to find the properties e.g Cp, ρ,μ and k. Hence we shall use graphs to
Reference: (PHT by Kern 1st Edition page 827, Fig17)
Using API gravity and temperature Ranges
Coulborn's Ratio (Kc)
As Kc=[ ((U1)/(U2))-1 ]
From Important Notes 1&2 it can be said that H.T coefficient is not constant and hence Kc≠0. Therefore Use Kc=0.43 i.e
Hence Kc
Now As we know that
Fc=((r/r-1)+(1/Kc))/(1+((ln(1+Kc))/(lnr))) - (1/Kc)
where r= ∆θ2/∆θ1
Now for Fc (Equation 1)
Numerator
Denomirator
1/Kc
Putting values Numerator, Denomirator and 1/Kc in Equation 1
Fc
As we know that
Caloric temperature θc= θmin. + Fc*(θmax. - θmin.)
Minor Check
LMTD=(∆θ1-∆θ2)/ln(∆θ1/∆θ2)
Now as we know that
Rsio= RSi * Ao/Ai = RSi * do/di
RDo=Rsio + Rso
Now for Amount of Heat Exchange
Qdot(hf)=ṁhfCphf∆T
Qdot(cf)=ṁcfCpcf∆t
Heat lost=Qdot (evolved)-Qdot (absorbed)
According to law of heat exchange Qdot (evolved)=Qdot (absorbed)
But here both fluids are moderatly hot that is why 50 Btu/hr heat is being lost to the environment
Normally Amount of heat exchange b/w both fluids is taken as representative of head duty/heat load, but here lets take QAM
Qdot (AM)
Fluid Allocation
Lube Oil (hf) Should be placed in annulus, because
1).It has wider Temperature Range TR=100°F
2). It has high viscosity
3). It has comparatively low flow rate (As Aa<Ap)
Crude Oil (cf) should be placed inside inner pipe, because
1).It has large no. of impurities hence it is more corrosive and errosive.
2).It has comparatively low viscosity
3).It has sufficiently high flow rates (Ap>Aa)
34° API Crude Oil (cf)
At 303.86°F calooric temperature (inside Inner Pipe)
Mass Flow Rate (lbm/hr)
72500
Mass Velocity/Mass Flux (G=ṁ/Af) in (lbm/ft^2.hr)
3111212.42097977
Linear Velocity (U=G/ρ) in (ft/hr)
65574.7509758562
Note: Up>>8ft/s i.e. upper limit and hence it is not acceptable. Therefore Crude Oil (cf) should be split into two parallel stream
Hence Flow rate Per stream (each parallel hairpin) is
34° API Crude Oil (cf)
At 303.86°F calooric temperature (inside Inner Pipe)
Mass Flow Rate (lbm/hr)
36250
Mass Velocity/Mass Flux (G=ṁ/Af) in (lbm/ft^2.hr)
1555606.21048989
Linear Velocity (U=G/ρ) in (ft/hr)
32787.3754879281
As Dynamic Pressure Drop is Pd=0.5ρU^2 (pdl/ft^2)
1967.75636322086
Reynold's Number Re=GD/μ OR ρDU/μ
133402.95218405
Re>10000 Hence Turbulent flow
Prandtl Number Pr=μCp/k
16.2338904109589
Dimensionless Ratio or (LHP/Dfc) ratio (x)
185.77648766328
Correction factor for end effects Ψ=1+x^(-2/3)
1.0307142207634
Note:As wall temperature (θw) is unkwon yet,therefore viscosity number can't be calculated right now
Hence take ɸ=(μ/μw)=1 i.e. isothermal condition and after finding wall temperature use
Nu'=0.023(Re^0.8)(Pr)^1/3*(ɸ)^n*(1+x^-2/3)
(Seder-Tate Equation for Turbulent flow)
755.914471648012
As Nu'=h'Dfc/k
Hance h'=Nu'k/Dfc
h'=Nu'k/Dfc (Btu/hr.ft^2. °F)
hi'
320.35852789727
Now as we know that
Wall temperature (θw)=(h'iotc+h'oTc)/(h'io+h'o)
Now find dynamic viscosity (μ) at wall temperature (θw) using data given on page 821 and Fig14 (PHT by Kern 1st Edit
μw (cP)
0.75
Viscosity number= ɸ= (μ/μw)
1.10666666666667
Viscosity Number Correction factor for turbulent and transition flow is (ɸ^(n))=(ɸ)^(0.14)
1.01429049584725
Now Correct Nusselt Number (Nu) for Non-Isothermal Condition during Turbulent or Transition flow
Nu=Nu'*(ɸ^(n))
766.716864265972
Now Correct Fil Coefficient (h) for Non-Isothermal Condition during Turbulent or Transition flow
hi=hi'*(ɸ^(n))
(Btu/hr.ft^2. °F)
324.936610109817
overall H.T coefficient based on outer surface of inner pipe under clean conditions (Uco)
Uco= 1/(1/ho + 1/hio + Rwo)
where Rwo=(do/2kw)*(ln(do/di))
Hence, Uco
As Rdo=Rsio + Rso
where Rsio= RSi * Ao/Ai = RSi * do/di
Rsio
Hence Rdo
Over all Design coefficient based on outer surface of inner pipe Under dirty/fouling condition (Udo)
1/Udo=1/Uco+Rdo
Hence Udo=1/((1/Uco)+Rdo))
Designe Equation
Qdot=UDoAo(LMTD)
Rearranging gives Ao= Qdot/Udo*(LMTD)
Ao
Overall H.T Length per stream (L) and L=Ao/(∏do)
L
No.of hairpins in series NHP=L/LHP
NHP
Therefore take NHP
NHP per stream (in parallel flow)
Therefore Length of flow channel for inner pipe
And Length of flow channel for Annulus
Pressure Drop Calculations
Important parameters and their formulas for P.Drop Calculations
Kinetic head (hk)= (U^2)/2g
Dynamic Pressure Pd=(1/2)ρ(U)^2
Total Pressure Drop=∆P=∆Psf + ∆Pff
Pressure Drop due to skin friction
and
Total Head Loss ∆h= hsf+hff
where
value of (g) in ft/s^2
Kinetic Head (hk)
Dynamic Pressure Pd
Darcy friction factor (fd)
Darcy friction factor (fd)
Friction Parameter (Kf)
Head loss due to skin friction (hsf)=Kf*hk
Pressure Drop due to skin friction ∆Psf=ρghsf
Loss Coefficient (KL)
K'L
KL=NHP*K'L
For Inner pipe
For Annulus
Head loss due to form friction (hff)=KL*hk
Pressure Drop due to form friction ∆Pff=ρghff
Total Head Loss ∆h= hsf+hff
Total Pressure Drop=∆P=∆Psf + ∆Pff
Note:As Total Pressure Drop is less than 10 psia i.e. allowable limit. Hence results are acceptable.
Calculations For Over design and Over surface
Ado=Qdot/Udo∆ΘLM
ACo=Qdot/UCo∆ΘLM
Ao=∏doLHPNHP
Over design= ∆d= (Ao/Ado)-1
Over surface= ∆c= (Ao/Aco)-1
Cold Fulid (cf) 26 °API
Hot fluid (hf) 34 °API
Symbol Amount/Value
ṁhf 6900
ṁcf 72500
t1 300
t2 310
TRc=(t2-t1) 10
T1 450
T2 350
TRh=(T1-T2) 100
Rsi 0.003
Rso 0.003
∆P 10
∆L 16
LHP=2*∆L 32
NPSi 2
NPSo 3
tAM=(t1+t2)/2 305
TAM=(T1+T2)/2 400
∆θ1=(T1-t2) 140
∆θ2=(T2-t1) 50
Outer Diameters of both pipies
NPS Outer Diameter (OD)
(inch) (inch)
2 2.38
3 3.5
De=(Di^2-do^2)/do
0.131240336134454
Ap (ft^2) Aa (ft^2)
0.0233028125984302 0.0204433905971293
De'=(Di-do)
0.0573333333333333
De/De'=(Di/do)+1 2.2890756302521
Inner pipe Annulus
di (ft) De (ft)
0.17225 0.131240336134454
Inner Pipe (xp) Annulus (xa)
185.77648766328 243.827476692962
Inner Pipe (Ψp) Annulus (Ψa)
1.0307142207634 1.02562191407846
o find the properties e.g Cp, ρ,μ and k. Hence we shall use graphs to find these properties and for Kc i.e. Coulborn's ratio.
Inner Pipe Annulus
0.43 0.1
icient is not constant and hence Kc≠0. Therefore Use Kc=0.43 i.e. greater value of Kc for furthur calculations.
0.43
Equation1
0.357142857142857
1.77002583979328
0.652614899929685
2.32558139534884
0.386624286721845
Fc<0.5
Therefore θc<ΘAM
For Cold Fluid (i.e. Crude Oil) For Hot Fluid (i.e. Lube Oil)
tc= t1+ Fc*(t2-t1) Tc= T2 +Fc*(T1-T2)
(°F) (°F)
303.866242867218 388.662428672185
tc<tAM Tc<TAM
87.410938933531 K or °F
0.00345428156748911 hr.oF.ft2/Btu
0.00645428156748911 hr.oF.ft2/Btu
427800 Btu/hr
427750 Btu/hr
50 Btu/hr
r heat is being lost to the environment
n as representative of head duty/heat load, but here lets take QAM
427775 Btu/hr
and errosive.
26° API Lube Oil (hf)
At 388.66°F calooric temperature (in annulus)
ss Flow Rate (lbm/hr)
6900
ass Flux (G=ṁ/Af) in (lbm/ft^2.hr)
337517.397968657
Velocity (U=G/ρ) in (ft/hr) Linear Velocity (U=G/ρ) in (ft/s)
6931.41879894165 18.2152086044045
ble. Therefore Crude Oil (cf) should be split into two parallel streams so that flow gets devided.While Ua>3ft/s i.e. lower allowable limit an
36250 (lbm/hr)
26° API Lube Oil (hf)
At 388.66°F calooric temperature (in annulus)
ss Flow Rate (lbm/hr)
6900
ass Flux (G=ṁ/Af) in (lbm/ft^2.hr)
337517.397968657
Velocity (U=G/ρ) in (ft/hr) Linear Velocity (U=G/ρ) in (ft/s)
6931.41879894165 9.10760430220225
sure Drop is Pd=0.5ρU^2 (pdl/ft^2) Note: Now Up/Ua is Close to upper
90.2575014371073
Note: Now Pd in inner pipe/annulus pipe is slightly/well bel
Number Re=GD/μ OR ρDU/μ
6101.3631901698
2100<Re<10000 Hnce Transition flow
dtl Number Pr=μCp/k
67.1820895522388
ss Ratio or (LHP/Dfc) ratio (x)
243.827476692962
tor for end effects Ψ=1+x^(-2/3)
1.02562191407846
cosity number can't be calculated right now
r finding wall temperature use correction factor ɸ^0.14 for turbulent and transition flow for making results realistic.
Nu'=0.116((Re^(2/3))-125)((Pr)^(1/3))*(ɸ)^n*(1+x^-2/3))
Hausen Equation for Transition Flow
101.03471480575
'k/Dfc (Btu/hr.ft^2. °F)
ho' hio'=hi'*(di/do)
51.5796140985968 278.227343346075
317.127802219212 °F
) using data given on page 821 and Fig14 (PHT by Kern 1st Edition)
μw (cP)
6.5
sity number= ɸ= (μ/μw)
0.461538461538462
ransition flow is (ɸ^(n))=(ɸ)^(0.14)
0.897406282797976
ndition during Turbulent or Transition flow
Nu=Nu'*(ɸ^(n))
90.6691878473818
tion during Turbulent or Transition flow
ho=ho'(ɸ^(n)) hio=hi*(di/do)
(Btu/hr.ft^2. °F)
46.2878697563758 282.203350040753
pipe under clean conditions (Uco)
0.000499382816400788 hr.oF.ft2/Btu
38.9911293851723 (Btu/hr.ft^2. °F)
0.00345428156748911 hr.oF.ft2/Btu
0.00645428156748911 hr.oF.ft2/Btu
ner pipe Under dirty/fouling condition (Udo)
31.1515410480192 (Btu/hr.ft^2. °F)
where Ao is Overall H.T surface
157.097791194249 ft^2
252.129983335648 ft
7.87906197923898
8
4
Lfc 128
Lfc 256
Inner Pipe Annulus
Re=Gcf*di/μcf Re'=Ghf*De'/μhf
133402.95218405 2665.42665062484
Turbulent Flow Transition flow
where
∆Psf=ρghsf
∆Pff=ρghff
Head loss due to skin friction (hsf)=Kf*hk
Head loss due to form friction (hff)=KL*hk
Friction Parameter (Kf)=(fd*Lfc)/Dfc
Darcy friction factor (fd) for turbulent and transition flow=0.014+1.056Re^(-0.42)
32.174
For Inner Pipe For Annulus
(ft) (ft)
1.28906036124655 0.0576108423256243
For Inner Pipe For Annulus
Pdp in (pdl/ft^2) Pda in (pdl/ft^2)
1967.75636322086 90.2575014371073
Note:Pd should be less than 2000 pdl/ft^2
For Inner Pipe For Annulus
fdp fda
0.0214318071784468 0.0524451791654101
For Inner Pipe For Annulus
Kfp Kfa
15.926103447554 234.173823250203
For Inner Pipe For Annulus
hsfp (ft) hsfa (ft)
20.5297086633539 13.4909512080561
For Inner Pipe For Annulus
Psf in (pdl/ft^2) Psf in (pdl/ft^2)
31338.6914002382 21135.9441885381
Loss Coefficient per hairpin
Total Loss Coefficient
K'L KL
0 0
K'L KL
1 8
For Inner Pipe For Annulus
hffp (ft) hffa (ft)
0 0.460886738604994
For Inner Pipe For Annulus
Pff in (pdl/ft^2) Pff in (pdl/ft^2)
0 722.060011496859
For Inner Pipe For Annulus
∆hp (ft) ∆ha (ft)
20.5297086633539 13.9518379466611
For Inner Pipe For Annulus
∆P (Psia) ∆P (Psia)
6.76414100137171 4.717830126643
owable limit. Hence results are acceptable.
157.097791194249 ft^2
125.511580918757 ft^2
159.509131019093 ft^2
Fraction Percentage
0.015349291715141 1.5349291715141
0.270871817974651 27.0871817974651
Units
lbm/hr
lbm/hr
O
F 422.03888889 K
O
F 427.59444444 K
O
F
O
F 505.37222222 K
O
F 449.81666667 K
O
F Important Note1:TRmax>100°F
hr.oF.ft2/Btu
hr.oF.ft2/Btu
psia
ft
ft
in
in
O
F 424.81666667 K
O
F 477.59444444 K
Units
K or °F Important Note2:∆θmax>50°F
K or °F
Since neither Schedule No. nor Pipe material is mentioned in Problem, therefore assume Commercial material i.e. Carbon steel
Outer Diameter (OD) Inner Diameter (ID)
(ft) (inch) (ft)
0.198333333333333 2.067 0.17225
0.291666666666667 3.068 0.2556666667
Value of pi
ρwater
Notie:Ap>Aa
>2 OK
c i.e. Coulborn's ratio.
ur calculations.
OK
Linear Velocity (U=G/ρ) in (ft/s)
1.92539411081713
le Ua>3ft/s i.e. lower allowable limit and hence it is acceptable.
Linear Velocity (U=G/ρ) in (ft/s)
1.92539411081713
Close to upper/lower allowable limit and is acceptable
r pipe/annulus pipe is slightly/well below the allowable limit of 2000(pdl/ft^2) and is acceptable.
g results realistic.
27≤Kcs≤32 (Btu/hr.ft. °F) 300≤T≤350
As wall temperature is 317.14 °F
Therefore Take Kw 28 (Btu/hr.ft. °F)
ft
ft
Note: It tells about skin friction
For Inner Pipe For Annulus
Pdp in (psia) Pda in (psia)
0.424720398410482 0.0194811729
For Inner Pipe For Annulus
Psf in (psia) Psf in (psia)
6.76414100137171 4.5619807433
Smooth pipe,long 180° bent
For Inner Pipe For Annulus
Pff in (psia) Pff in (psia)
0 0.1558493833
Allowable limits
Slightly below the allowable limit (OK) 5≤∆d≤20%
OK 20≤∆c≤40%
TRmax>100°F
∆θmax>50°F
mmercial material i.e. Carbon steel and Schedule No=40
3.141592654
62.428 lbm/ft3
[Reference: PHT by Kern 1st edition Page821]
Properties at Ca
Thermal Conductivity (k) [Reference: PHT by Kern 1st edition Page803, Fig1 (Caloric Temp (θc) vsThermal conducti
Specific Heat Capacity (Cp) [Reference: PHT by Kern 1st edition Page806, Fig4 (Caloric Temp (θc) vs Specific Heat (Cp
Specific Gravity (s) [Reference: PHT by Kern 1st edition Page809, Fig6 (Caloric Temp (θc) vs Specific gravity (s
Density (ρ) ρ=s*ρwater
X and Y=f(API)
Dynamic viscosity( μ)
[Reference: PHT by Kern 1st edition Page823, Fig14 (μ=f(θc,X,Y))]
Fluid Stream Caloric Temperature (θc) Thermal Conductivity (k)
API Gravity
(°F) (Btu/hr.ft.°F)
Crude Oil (cf) 34° 303.866242867218 0.073
Lube Oil (hf) 26° 388.662428672185 0.067
Kern's Criteria for Variable H.T coefficient
1 μ of either fluid>1cP
2 TR of either fluid≥100°F
3 ∆θ at either terminal end ≥ 50°F
Hence H.T Coefficient will be veriable and Kc≠0
Properties at Caloric temperatures using Graphs
mp (θc) vsThermal conductivity (k))] Viscosity of Lube oil(cP) Temperature (°F)
mp (θc) vs Specific Heat (Cp))] 1.4 500
mp (θc) vs Specific gravity (s))] 3 400
7.7 300
Specific Heat Capacity (Cp) Density (ρ)
Specific Gravity (s)
(Btu/lbm °F) (lbm/ft3)
0.59 0.76 47.44528
0.62 0.78 48.69384
riable H.T coefficient
μLube oil (hf)>1cP OK
TR(Llube oil)=100°F OK
∆θ1>50°F OK
t will be veriable and Kc≠0
Dynamic viscosity( μ)
(cP) (lbm/ft.hr)
X=10.3
0.83 2.0086
Y=21.3
Using given data and interpolation 3 7.26
