Classification: Internal Use

Fluid Allocations in Shell and Tube Heat Exchanger

Fluid allocation in shell and tube heat exchangers is a key decision during the design of the exchanger to
ensure the achievement of the required thermal duty with optimized cost and satisfactory in-service
reliability. The selection of the correct side for each fluid depends on many interacting factors, some related
to the thermal design and some others related to the mechanical design and future considerations of
inspection and integrity monitoring of the exchanger.

The best choice of routing can only be decided after designing Shell side fluid in
both options in many cases. In some cases, the selected side
for each fluid is a tradeoff decision as there might be no one
single selection satisfies all the required factors and some of
the factors might conflict with other. Hence, understanding the Tube side fluid in Tube side fluid out
effect of each parameter and the main features of each heat
exchanger type is very important to help in selecting the right
optimized design.

In addition, each of the exchanger types either being fixed

tubesheet, floating head tubesheet or U tube heat exchanger Shell side fluid out
has its own characteristics, which will be preferred to be used
for specific fluid applications over other types.

Main Factors affecting fluid allocation:

Allowable pressure drop: Flow areas in shell side is higher than that of tubeside and flow resistance and
associated pressure drop will be less. Fluids of which pressure drop should be low to satisfy the limiting
operating conditions in the plant should be allocated in shell side

Fluid operating pressure and temperature: It is preferred to have the higher pressure fluid in tube side of
the exchanger not in shell side as the thickness of the pressure part is proportional with its diameter. An
example for that is the equation of the thickness required for the cylindrical part under internal pressure
(t=PR/SE-0.6P) [6] where t is the required thickness and R is internal radius and S is the material allowable
stress. Thick shell will impact the cost, foundation design, and might impact the fabricability of the shell
(welding, forming and inspection requirements).

In some cases, routing the higher-pressure fluid through the shell may produce a cheaper unit, particularly
if it reduces the exchanger diameter and it is made of carbon steel. [1]

Impact of temperature is sometimes similar as at high temperature the material strength is reduced and so
the allowable stress value (S in the equation). That will result in higher calculated thickness which preferred
to be in tube side.

While allocating the higher pressure fluid in tubeside it is worth to consider the
10/13 rule during the determination of the shell side design pressure if
possible. Sometimes minor increase in shell side design pressure can achieve
the 10/13 rule explained below

10/13 Rule: Loss of containment of the low-pressure side of shell and tube
heat exchangers to atmosphere is unlikely to result from a tube rupture where
10/13 Rule for Overpressure Protection
the pressure in the low-pressure side during the tube rupture does not exceed
the corrected hydrotest pressure. In such case, the exchanger can be
considered as protected from overpressure scenario by design and there will be no need to use
overpressure protection device (PSV or Rupture disk). [5]
Classification: Internal Use

Fluid viscosity: For highly viscous fluids, turbulent flow can be obtained easier at the shell side due to the
effect of baffles in changes of flow direction. It is preferred to pass higher viscous fluids in shell side.

Viscous fluids also tend to have a higher pressure drop which supports routing them to shell side to
minimize the pressure drop.

Fluid heat transfer rate: fluid with low heat transfer coefficients is preferred to be located in shall side as it
can be more flexible to enhance the heat transfer by changing the flow patterns using the baffles as the
heat transfer is much higher for turbulence flow. If that fluid to be located in tube side, then higher number
of tube passes can be used the velocity and flow turbulence.

Fluid phases (one phase or two phases): Fluids which undergo phase change s preferred to be located in
shell side. In shell side a large flow area can be used to accommodate vapor flow without increasing the
pressure drop. While flow which is condensed during the heat transfer is usually located in the tube side.

Dirty Fluids: Dirty fluids and fluids that contain suspended solids is better to be located in tube side as it is
much easier to be cleaned compared to shell side.

In case dirty fluids need to be located in shell side due to other considerations, it is preferred to use
square tube pitch instead of triangular pitch (despite of the less heat transfer) in order to facilitate
cleaning the tube bundle from shell side. The table below summarizes the main features of each of each
tube pitch.

Triangular Square

30° 60° Rotated 90° 45° Rotated

Applicable shell side fluid Low fouling tendency due to the No limitation
difficulty of mechanical cleaning

Pressure drop(Shell side) Larger than square Smaller than triangular

Larger than Smaller than Smaller than Larger than

rotated triangular rotated square square
triangular

Heat Transfer coefficient Higher than triangular Lower than triangular

(shell side)

Fluid corrosivety: Corrosion effect on selecting the ideal exchanger side for each fluid is difficult to
conclude, however as a general rule, it is usual to route the more expensive material in tube side. In
some cases if the fluid is not at high pressure, and the switch reduces the shell diameter, it may provide
cheaper solution. [1]

When shell side fluid is prone to develop cracking, fixed tubesheet exchangers shall be avoided and all
internal welds shall be accessible for inspection. In addition, if a fluid has tendency to cause crevice
corrosion it is better to be routed in tube side to avoid crevice corrosion between tube and tubesheet at
backside of tubehseet
Classification: Internal Use

Cooling water: Low velocities can promote increased corrosion. There must
be sufficient velocity to maintain any particulate in suspension as it travels
through the heat exchanger [7]. Velocities below about 3 fps (1 m/s) are likely
to result in fouling, sedimentation and increased corrosion in fresh and
brackish water systems. Accelerated corrosion can also result from dead
spots or stagnant areas if cooling water used on the shell side of heat
exchangers rather than the preferred tube side. Velocity limits depend on
the tube material and water quality.
[2]
With very few Exceptions, cooling water should be on the tube side to minimize stagnant areas.

Bundle with cooling water in shell side

On other hand, high water velocity can increase the corrosion by erosion corrosion mechanism and also
by allowing more Oxygen to be carried to cathodic sites increasing the cathodic reaction rate. Hence, both
very and very low water velocities shall be avoided. [3]

Main features of shell and the heat exchanger types affecting the selection of fluid allocation

Fixed tubesheet heat exchanger: Fixed tubesheet

heat exchanger has straight tubes that are
secured at both ends to tubesheets welded to the
shell barrel.

The principal advantage of the fixed tubesheet

construction is its low cost (as expansion joint is
not required) because of its simple construction

The outsides of the tubes cannot be cleaned

mechanically (but can be chemically cleaned). Fixed Tubesheet Heat Exchanger
Thus, its application is limited to clean services on the
shell side. Shell internal and tube bundle external surface cannot be inspected

U tube heat exchanger: The tubes of a U tube heat exchanger are

bent in the shape of a U and there is only one tubesheet.

In U tube heat exchanger one end is free and the bundle can
expand or contract in response to stress differentials. In addition,
the outsides of the tubes can be cleaned, as the tube bundle can
be removed.

The main disadvantage of the U tube construction is that the insides

of the tubes cannot be cleaned effectively, since the U bends would
require flexible end drill shafts for cleaning. Thus, U tube heat U Tube Heat Exchanger
exchangers should not be used for services with a dirty fluid inside tubes
Classification: Internal Use

Another limitation is the inspection of U bend area as most of the commercially available inspection
techniques could not pass through the bend areas unless using smaller probe
Fill Factor (FF) and hence less accuracy in the inspection results. A large fill d
Defect
factor (e.g. 85%) is desirable for optimal NDE (Non Destructive Examination)
performance. [4]

Compared to fixed tubesheet the cost will be in the same range as it will save
the cost of the second tubesheet and added a cost for the bending of the tubes D
and in many cases the stress relief heat treatment required for the U bend 𝑑2
area. In addition, a relative larger shell diameter due to the minimum U bend 𝐹𝑖𝑙𝑙 𝐹𝑎𝑐𝑡𝑜𝑟, 𝐹𝐹 = X100 [4]
𝐷2
radius limitation contributed to increase the cost as well.

Floating head heat exchanger: Floating head heat exchanger is the most versatile type of shell and tube
heat exchangers, and also the highest in cost.

In this design, one tubesheet is fixed relative to the shell,

and the other is free to float within the shell. This permits
free expansion of the tube bundle, as well as cleaning of
both the insides and outsides of the tubes

Floating head shell and tube heat exchangers can be

used for services where both the shell side and the tube
side fluids are dirty making this the standard construction
type used in dirty services, such as in petroleum Floating Heat Exchanger
refineries.

Guidance for selecting TEMA type based on whether fluid is clean or dirty

U-Tube Fixed Tubesheet Floating Tubesheet

References:
[1] Heat Exchangers – Selection, design & construction; E.A.D Saunders
[2] API RP 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry, Third Edition
[3] The Nalco Water handbook, Nalco Company, Daniel J. Flynn, Third Edition
[4] API RP 586 – Section 1, Heat Exchanger Tubing Inspection – First edition
[5] API Standard 521, Pressure-reliving and Depressuring Systems, Seventh Edition
[6] ASME BPVC Sec. VIII div1 - 2021
[7] TEMA, Tubular Exchanger Manufacturer Association, Tenth edition
[8] API Standard 660; Shell-and-Tube Heat Exchangers, 2015 edition