HP Boiler Feedwater Heater 1

HP Boiler Feedwater Heater

© 1998 AEA Technology plc. - All Rights Reserved

TASC 2.pdf 1
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Workshop
The purpose of this exercise is to design a simple single-phase heat
exchanger using the TEMA input sheet and to introduce the NEL40
databank and stream data. As this is the first example, it will lead you
through the data input in some detail.

The Design calculation will determine the shell length and diameter,
the nozzle sizes, the number of tubes and passes, the number of baffles
and baffle cut. Other details such as shell and header type, baffle type,
tube type and layout will remain as initially set.

Data can be entered on the TEMA sheet in any of the areas marked light
blue. The data in this sheet is linked to the normal data input forms in
TASC and vice versa so either method of input can be used at any time
(the next example illustrates the use of the main input forms). As you
move the cursor around the sheet you will find in some cases drop
down boxes become available. Help may be obtained at any time by
placing the cursor on an item and pressing F1. You may also enter data
in grey fields but these data are not necessary for a run of TASC - they
are treated simply as comments.

The TASC design logic will attempt to optimise the heat transfer against
the allowable pressure drop on both the shell and tube sides. It also has
built in heuristic rules, which will stop it searching once it realizes that
further calculations are pointless. As a general rule, TASC will attempt
to design small diameter single pass exchangers before increasing the
tube length, shell diameter, number of passes and number of shells.

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Learning Objectives
Once you have completed this section you will be able to:

• Input data using the interactive TEMA sheet

• Enter physical properties using the NEL40 database
• Enter physical properties using the property table
• Save datasets

Process Overview
The details of the process data and some basic geometry are shown in
the table on the following page:

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Cold Side Hot Side

Boiler
Fluid Fuel Oil
Feedwater

Total Flowrate 130291 626103 lb/h

Liquid 626103 lb/h

Water 130291 lb/h

Temperature 122 / 332.6 415.5 / 332.6 °F

(In/Out)

Density (In/Out) 54.9 / 56.8 lb/ft³

Specific Heat 0.5589 / .5207 Btu/lb °F

(In/Out)

Viscosity (In/ 1.94 / 3.37 cP

Out)

Themal 0.058 / 0.0618 Btu/h ft °F

Conductivity
(In/Out)

Inlet Pressure 725 174 psi (abs)

Allowable 14.5 21.7 psi

Pressure Drop

Fouling 0.0005 0.003 h ft2 °F/Btu

Resistance
(min)

Notes:

• Heat Exchanged: 27900 k Btu/h

• Exchanger to be Horizontal

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Building the Simulation

The New option will clear any existing data and call up the start up
screen.

1. Set the calculation mode to Design. As we will be using the

NEL40 databank for a single component and entering data in the
property table, then the number of components may be set at 0.
2. Select the basic mode to minimize the amount of input needed,
and then enter any comments into the remainder of the input
lines.
3. Click OK and the exchanger geometry will now appear.

To change the units you have two options:

• In the menu bar, select File, then Preferences, and select the
Units tab.
• Click on the Units box in the lower left hand corner – this will
call up the Units tab of the Preference screen to be displayed

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4. Select the geometry units as US/British and change the process,

option, stream and component units as required.
5. Click OK.

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6. Select Input from the menu bar, then Exchanger Geometry.

7. In the Exchanger General tab, enter the side that you want to
place the hot stream on. From the data supplied, the largest
fouling factor is the “hot side”, while the highest pressure is on
the “cold side”. These two requirements are in conflict.
Therefore, it is probably best to try both sides and see which
exchanger works out cheaper. For this example, we will set the
hot stream to be on the tube side.
8. Select Apply or OK.
9. From the menu bar, click on Input and select Physical Property
Data, where the following screen will appear.

If the output to databank is

ticked, then the stream data
supplied will be saved to a
user databank, specified in the
Preferance screen. To call the
data at a later stage, select
User Databank from the
Datasource and select the
appropriate fluid from the
code box.

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10. For the Hot Side tab, set the phase for the fluid stream to single
phase liquid, and as the physical property data is supplied, leave
the data source as Input Directly.
11. On the right hand side, the Property Table button is active, so
click on this to permit the single-phase physical property data to
be entered.

Ensure that the data supplied

encompasses the inlet/outlet
temperature range. Also, data
must be entered from the left
hand column.

12. Enter the density, specific heat capacity, viscosity and the thermal
conductivity for the two temperature levels given, then click OK.
13. Now switch to the Cold stream tab, and set the phase to Single
Phase Liquid.

If the reference pressure is left

blank, then TASC will
evaluate the physical
properties at the inlet pressure
minus half the allowable
pressure drop. To calculate the
physical properties at another
pressure, enter the value here.

14. For the Data Source select Single Component from NEL 40. You
will then notice that the Code becomes not set, and you can
select water from the drop down box.
15. Click OK .
16. From the menu click onto Input and select TEMA Input, where
the screen on the next page will appear:

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17. Enter the details for the flow rates, inlet/exit temperatures, inlet
pressure and pressure drop as shown. Set the fouling factors and
the exchanger to be horizontal and enter the tube material as
stainless steel. It is at your discretion to select the shell type and
front and rear headers and the baffle type required. Once the
data has been entered close the TEMA input sheet.

Note:

There is no need to enter nozzle sizes as these will be determined by

TASC based upon the pressure drop requirements. The same applies to
the baffle cut and pitch.

Now all the data has been entered, but before running it is important to
save the dataset. This is achieved from the menu by File, then Save As.
Now you can run by clicking on the Run button or from the menu Run,
Calculate All.

Save your case!

If you have warnings or errors in your dataset, then the Error Message /
Log will appear giving an indication of the warnings or the reason for
the program not to complete a design. If this appears then you can
make the necessary changes to the dataset, save and re-run. If the run
has been successful, then the Results Summary screen will pop-up.

Results
Record the appropriate information in the table on the next page:

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Units

Front head

Shell type

Rear head

Baffle type

Side hot stream placed upon: Tubeside

Area for heat transfer

Area Ratio

Shellside pressure drop

Tubeside pressure drop

What is the consequence of changing the side the hot fluid

is placed upon?__________

Record your results in the following table:

Units

Side hot stream placed upon Shellside

Area for heat transfer

Area Ratio

Shellside pressure drop

Tubeside pressure drop

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Continuation Exercise
The Design mode of TASC will provide a number of designs that will
achieve the required duty. However you, the engineer, will probably
want to fine tune and fully optimise the design. This is best achieved
via Rating/Checking mode.

1. Select File from the main menu and click on Create Checking
Case. This will then prompt you for the name of a data file, which
will be used to save the Rating/Checking data.
2. Enter the dataset name. You will then be shown a table of
possible designs:

The possible designs are presented in a spreadsheet type format.

Scrolling to the right will reveal a column headed Cost Item/Chosen,
which shows ratios of the costs of alternative designs to the cheapest
design. The design with the ratio of 1 is the design for which TASC has
shown full details.

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To select the design you wish to look at in more detail, click on the
Design Number on the left-hand side of the table. The table of
alternative designs will close and the Process Diagram will be
displayed. TASC will now have changed to a Checking type calculation,
where the number of tubes, baffle cut and pitch have been added to the
dataset for the design selected.

3. Run the dataset and check the results.

Save your case!

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