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  • Submitted: Feb 18 2011 02:12 PM
  • Last Updated: Apr 16 2012 07:24 PM
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Previous Versions

  • 10 Nov 2011 Download Process Heat Transfer 1.03
  • 30 Jun 2011 Download Process Heat Transfer 1.02
  • 26 Apr 2011 Download Process Heat Transfer 1.01

Download Process Heat Transfer 1.04

* * * * * 19 Votes
heat transfer exchanger shell tube tema coefficient

Derived from a collaboration between Dale Gulley from Gulley & Associates and Art Montemayor, this workbook contains invaluable information related to process heat transfer derived almost entirely their combined years of experience.

MS Excel spreadsheet includes:
  • Notes and Experiences (expanded below)
  • TEMA Designations
  • Tube Counts
  • Heat Balance
  • Shell and Tube Spec Sheet
  • Plate Exchanger Spec Sheet
  • Typical U-values
  • Shell Side Pressure Drop Calculation
  • Shell and Tube Rating
  • Sample Condenser Calculation
  • Condenser Tube Data
  • Tubesheet Thickness Calculation
  • Tubesheet Layouts
Notes and experience section includes the following:

Air Coolers:

1. Air flow accessories - don't overlook these when calculating fan HP
2. Box header design - limit of process temperature change
3. Connecting bundles of existing coolers for a new service
4. Fan drive changes that increase capacity of existing cooler
5. Fan drive noise - suggestions on how to reduce
6. Maximum motor HP for a fan
7. Maximum tube wall temperature for wrap-on fins
8. Optimum number of tube rows
9. Overall heat transfer rate estimate for hydrocarbons
10. When do bare tubes become more efficient than fin tubes?
11. When To limit number of tube passes in air coolers
12. When to use wind coolers


1. Avoid mist flow boiling inside tubes
2. Kettle reboiler - liquid carryover problem solutions
3. Kettle reboiler - shell nozzle arrangement problem
4. Kettle reboiler - shell vapor outlet nozzle location
5. Kettle reboiler - sizing shell vapor space
6. Kettle reboiler - undersized shell effects
7. Estimate - pool boiling heat transfer coefficient for hydrocarbons
8. Large boiling temperature difference problems
9. Lowest limit of boiling temperature difference
10. Vertical thermosyphon - choking two phase flow with small outlet nozzle
11. Vertical thermosyphon - minimum recirculation rate
12. Vertical thermosyphon - check for liquid preheat zone
13. Vertical thermosyphon - who sets recirculation rate
14. Kettle Reboilers - Support or Baffles


1. What diameter to use to start design of a coil
2. Estimate - gas heat transfer coefficient inside tubes
3. Estimate - hydrocarbon heat transfer coefficient in tubes
4. Estimate - latent heat of hydrocarbons
5. Estimate - liquid thermal conductivity of light hydrocarbons
6. Estimate - overall heat transfer coefficient in shell & tube
7. Estimate - tube length that lowers tube pressure drop
8. How to calculate excess surface and overdesign surface
9. Use superficial velocities to calculate best heat transfer flow pattern
10. L/D equation for heat Transfer coefficient inside tubing
11. LMTD correction factor charts for TEMA G and J type shells
12. Low LMTD correction factor for divided flow
13. What is the lowest LMTD correction to use in shell & tube
14. Minimum flow area for shell side inlet nozzle
15. How to calculate performance of heat exchangers with plugged tubes
16. How to increase heat transfer for low Reynolds numbers
17. Calculate when to use seal bars on a bundle to increase heat transfer
18. Calculate S & T bundle diameter from number of tubes
19. Equation for calculating tube count in shell & tube
20. Check for hot tube wall temperature of cooling water
21. Sometimes larger tubes are better than small ones
22. Weighted MTD


1. Avoid small baffle cuts in S & T condensers
2. Estimate - Condensing heat transfer coefficient for hydrocarbons inside tubing
3. Maximum heat transfer rate inside tubes for total condensation
4. Quick estimate for reflux condenser LMTD in air cooler
5. Reflux (Knockback) condenser comments
6. Steam condenser types
7. Sulfur condenser - design within tube velocity limits
8. Warning about small temperature pinch points in condensers
9. When to slope single tube pass tubes in condensing service
10. Zone those condensers!


1. Benefits of using rotated square pitch in shell & tube
2. Caution when using a longitudinal baffle in the shell side
3. Using turbulators for tube side laminar flow
4. Discussion of types of triple segmental baffles in shell & tube
5. Check entrance and exit space for shell nozzles
6. Horizontal vs vertical baffle cut in shell & tube
7. Is expansion joint required in the shell of a fixed tube sheet?
8. Increasing capacity of existing shell & tube exchangers
9. Locating vents on the shell side of vertical exchangers
10. Optimun gasket location for flanges
11. Reinforcing rods as tube inserts to increase heat transfer
12. Shell side impingement protection
13. Special shell & tube heat exchanger type (NTIW)
14. When to consider by-pass strips in shell & tube bundle
15. What is too large of temperature change in 2 tube passes?
16. When to rotate square tube pitch in shell & tube exchanger?
17. Design Temperatures of Carbon Steel and Low Alloy Tubes and Tubesheets
18. Design Temperatures of Nonferrous Tubes and Tubesheets

Heat Recovery:

1. Deciding on what fin spacing to use
2. Estimate of nozzle size for HRSG
3. Face area estimate for HRSG units
4. Maximum exhaust gas temperaure for steel fin tubes
5. When to use bare tubes in waste heat boilers


1. Cooling water flowing inside 304SS U-tubes

Pressure Drop:

1. Allowing for fouling in pressure drop calculations
2. Allowable pressure drop suggestions
3. Allowable shell side pressure drop if a multi-leaf(a.k.a. lamaflex) long baffle is used
4. Better baffle window pressure drop equation
5. Designing for better use of tube pressure drop
6. Effect of 1st tube rows on shell nozzle pressure drop
7. Pressure drop on kettle side
8. Reducing high shell side pressure drop in fixed tube sheet exchangers
9. Use impingement rods instead of plate to lower shell press. drop
10. What design pressure drop to use for heavy liquids inside tubes
11. Maximum velocity inside tubes
12. Calculate shell nozzle pressure drop
13. Improve shell side pressure drop calculations

Tube Bundle Vibration:

1. Features of a new S & T bundle that replaces bundle that vibrated
2. Vibration cure when designing shell & tube bundles
3. Conditions likely to cause shell & tube bundle vibration
4. Cures for vibration in existing bundle


1. Allocation of streams in shell & tube
2. Articles published by Dale Gulley
3. Avoid these fluids when using lowfin tubing
4. Best heat transfer flow pattern
5. Check liquid thermal conductivity at high reduced temperatures
6. Check piping connections when there is under-performance
7. Evaluating an exchanger for a new service
8. Check heat release curve data for skipping over dewpoints and bubblepoints
9. When will exchangers with low-fins be more economical than exchangers with bare tubes?
10. Problems with excess heat exchanger surface
11. Purchasing warning for shell & tube exchangers
12. What is the minimum velocity inside tubing for slurries?
13. Suggestions for low-fins and potential S & T bundle vibration
14. Choose shell & tube or multi-tube heat exchangers
15. Thermal design problem with shell side long baffle
16. Trouble shooting article in Hydrocarbon Processing
17. Under-surfaced S&T quote
18. When to add shell in Series
19. When to consider a long baffle in the shell
20. Which stream goes inside the tubes of gas/gas exchangers?
21. Weighted MTD
22. Why did performance decline in a TEMA type F,G or H type shell?
23. Zone those condensers
24. Fouling factors for water
25. Fouling Factors for Liquid Hydrocarbons

What's New in Version 1.04 (See full changelog)

  • 4/16/2012 - Added:
  • Boiling
  • Vertical Thermosyphon-Calculate Pressure Drop at The Outlet Nozzle
  • Vertical Thermosyphon-Design for a Smaller Liquid Preheat Zone
  • Calculations
  • Estimate - Hydrocarbon Gas Heat Transfer Coefficient in Shell Side
  • Vibration
  • Best Design Feature to Prevent Bundle Vibration
  • Misc
  • Viscous Flow - Use More Pressure Drop Than Usual

Disclaimer: All software provided "As-Is" with no warranty, expressed or implied, available. See our Terms of Use for more information.

Thanks for sharing this informative spreadsheet. It is really useful.
This extensively well written covers all aspects of shell and tube heat exchangers. Many thanks to the author.
I have a small comment:
For removable tube bundles (U tube) I usually use a type "I" shell where one end is capped. It looks like the ketle type except there is no enlargement for liquid vapor disengagement. However no ASME classification is given neither in Perry or elsewhere. The only place I can find it is in the Chinese code. Why is this popular type ignored ?
Its a good spreadsheet which covers lots varoius types of heat transfer equipments.

nice work...
really appreciated.
very very very........... appreciated upload... thank you so much.......... it really help me alot in my design work.....
what a great share...thank you very much!!
Many thanks to you.. Simply superb
a great share, thank you so much!
God Bless you... it's really nice spreadsheet
Superb compilation. All your experience condensed at one place and handed-over on a platter!

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