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Shell & Tube Exchanger - Performance & Fouling

TEMA · ASME PTC 12-5 · ISO 5167

Counter-current heat exchange · E-105

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TimestampU (W/m2/K)Rf (1e-4)Q (kW)LMTD (C)Imb %H.App (C)C.App (C)Shell DPTube DPStatus
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Formulas (mirrors engine.py)

Duty: Q = m × Cp × ΔT / 3600 [kW]. Computed independently for hot & cold streams; reported as average.

LMTD: Log-Mean Temperature Difference for counter-current flow: LMTD = (ΔT1 − ΔT2) / ln(ΔT1 / ΔT2).

Overall U: U = Q × 1000 / (A × F × LMTD) [W/m²/K]. F is the LMTD correction factor, set automatically when a TEMA shell type is selected: 1-2 shell (F = 0.90), 1-4 shell (F = 0.85), 2-4 shell (F = 0.88). Select "Custom F" to enter any value manually.

Fouling resistance: Rf = 1/U − 1/Uclean [m2K/W]. Reported as Rf × 10⁴.

Q imbalance: |Q_hot − Q_cold| / avg(Q_hot, Q_cold) × 100 [%]. Energy balance check.

Alert tiers

Fouling alarm: Rf >= 12.0 × 10⁻⁴ m2K/W (user-configurable). Signals fouling accumulation; consider cleaning schedule.

Approach low: Either hot or cold stream approach < 10 C (user-configurable). Indicates thermal constraint or fouling.

Pressure drop: Shell DP > 0.55 bar or Tube DP > 0.45 bar (user-configurable). Process or fouling-induced.

Imbalance high: Q imbalance > 8%. Instrumentation error or unbalanced heat input/removal.

Scope

Reference-grade PoC. Not a control system, not instrumentation design guidance. Assumes inlet/outlet measurements are calibrated.

U values are not clamped; negative or zero U signals data error.

Engineering Manual - Shell & Tube Exchanger

1. Purpose & Scope

Shell-and-tube heat exchanger monitoring dashboard computing overall heat-transfer coefficient U and fouling resistance Rf, with energy balance and pressure-drop trending per ASME PTC 12-5 and TEMA standards.

2. Key Standards

ASME PTC 12-5 - Single-Phase Heat Exchangers. Defines U measurement, LMTD correction F-factors, and fouling-resistance protocols.

TEMA - Tubular Exchanger Manufacturers Association. Classifies shell & tube types by shell-pass/tube-pass count. Each configuration has a distinct LMTD correction factor F range: 1-2 shell (0.85-0.95, default 0.90), 1-4 shell (0.80-0.92, default 0.85), 2-4 shell (0.82-0.95, default 0.88). Selecting a TEMA type auto-sets F; select "Custom F" to override.

ISO 5167 - Flow measurement via orifice / venturi plate in ducts and pipes.

3. Input Tags

Timestamp, hot-stream inlet/outlet T and flow, cold-stream inlet/outlet T and flow, Cp values, shell DP, tube DP.

4. Calculations

Q_hot = m_hot × Cp_hot × (T_h_in − T_h_out) / 3600 [kW]

Q_cold = m_cold × Cp_cold × (T_c_out − T_c_in) / 3600 [kW]

Q_avg = (Q_hot + Q_cold) / 2

LMTD = (dT1 − dT2) / ln(dT1 / dT2), where dT1 = Th,in − Tc,out, dT2 = Th,out − Tc,in

U = Q_avg × 1000 / (A × F × LMTD) [W/m2/K]

Rf = 1/U − 1/Uclean [m2K/W]

5. Alert Thresholds

Fouling: alarm Rf >= 12.0 × 10⁻⁴. Approach: advisory < 10 C either stream. Shell DP: advisory > 0.55 bar. Tube DP: advisory > 0.45 bar. Imbalance: advisory > 8%.

6. Assumptions

Steady-state operation. Cp constant per stream. LMTD applicable (true counter-current approximation). F-factor defaults are mid-range values for each TEMA shell type; actual F depends on P and R ratios for the specific exchanger.

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