1 1Table of ContentsSimulate a Water Cooler 1-1Workshop 1-2Simulate a Condenser 2-1Workshop 2-2Design a Steam Condenser 3-1Workshop 3-2Design a Vapour Cooler 4-1Workshop 4-2 2 2Module 1 - 1Simulate a Water CoolerModule 1 - 1Module 1 - Simulate a Water CoolerModule 1 - 2WorkshopModule 1 - 2 Simulate a Water Cooler WorkshopThe purpose of this module is to determine the tubeside outlet temperature for a forced-draught air-cooled heat exchanger by simulating a water cooler.Learning ObjectivesOnce you have completed this section, you will be able to: Input data using the card system Be aware of the API Input system Enter physical properties by the in-built NEL 40 databank Save datasetsWorkshop Module 1 - 3Simulate a Water CoolerModule 1 - 3Process OverviewDetails of the process data and some basic geometric data are shown in the following tables:Geometric SpecificationsBundle DetailsRow and Pass arrangement: Row 4, Pass 1 Row 3, Pass 2 Row 2, Pass 3 Row 1, Pass 4Item Value UnitsInlet Nozzles 4Outlet Nozzles 4Inside diameter, Inlet Nozzles 101.2 mmInside diameter, Outlet Nozzles 101.2 mmTubes 162Rows 4Passes 4Effective tube length 6020 mmTransverse Pitch 58.4 mmLayout angle 30 degTube inside diameter 21.32 mmTube outside diameter 25.4 mmFin root diameter 25.4 mmFin frequency 433 /mFin tip diameter 57.16 mmMean fin thickness 0.457 mmModule 1 - 4WorkshopModule 1 - 4 Simulate a Water Cooler Process DataBuilding the Simulation1. Set the calculation required in the Simulation mode for the tubeside outlet temperature.2. From the menu bar, select Input-Simulation-Tubeside Outlet Temperature.The type of calculation being performed is indicated in the top right hand corner of the process diagram, which will also summarize the process conditions for the tube and air side as the simulation is built.Next, we can begin entering the geometric data for the exchanger.3. Select Input-Geometric Data from the main menu bar.Before entering data however, it is necessary to establish the units that the data will be entered in.On the lower right hand side, there is a box marked Units System, which has a scroll down arrow.From the drop down menu, select SI.4. Enter the geometric data from the table given at the beginning of this module.If information is not supplied, the default values of the program may be assumed.Item Tubeside X-side UnitsTotal mass flow 30500 177500 kg/hInlet temperature 92 37 CEstimated outlet temperature56 CInlet Pressure 1.2 barPressure drop 0.18 barFouling factor .00002 m2 K/WThe New option will clear any existing data.Workshop Module 1 - 5Simulate a Water CoolerModule 1 - 55. On the Bundle Specification tab, enter the details of the number of tubes andpasses for the bundle.You will notice that 162 tubes are specified with 4 passes, implying that each row will not have the same number of tubes.In this example you may assume that there will be an extra tube in every odd row.Select this entry from the Type of Bundle drop down menu.Enter the remaining data concerning the number of tubes, rows and passes, ensuring that the symmetrical bundle is unticked.Clicking on the OK button will give a pictorial representation of the pass layout.Each pass is indicated by a different colour.6. In the Pass box, click Pass number 4.Move the mouse so it is positioned over the first tube in the bottom row, and click.Hold, move to the last tube in the row and release the mouse.The entire row will now change colour and be designated as Row 1 = Pass 4.7. Repeat this for Pass 3-Row 3, and Pass 2-Pass 1.Click Accept.(It is indicated that the X-side flow direction is upwards, so the exchanger has been specified as counter-current).Enter the remaining geometric data and close the view when complete.8. Enter the process conditions for the tubeside (ensuring that you have the correct unit system). Module 1 - 6WorkshopModule 1 - 6 Simulate a Water Cooler For the tubeside fouling, ACOL has many different options to consider such as a fouling resistance, thermal conductivity and a thickness layer.In this example select,Constant Rf in item 240.2 from the Fouling Option, andenter the fouling resistance as shown.Accept the process data for the tubeside and close the window.9. Enter the process data for the X-side.ACOL will automatically pick up the physical property data for air on the X-side.However, we need to enter physical property data on the tubeside.10. From themenu bar, select Input-Physical Property Data- Tubeside.As we are calling water property information from the NEL 40 databank, ensure that the Data Input Method is set to Calculate From Components.Workshop Module 1 - 7Simulate a Water CoolerModule 1 - 711. Set the Number of Components to 1. Also, as at the specified temperatures and pressures, water will be a single-phase liquid. Enter this in the Stream Phase box.Module 1 - 8WorkshopModule 1 - 8 Simulate a Water Cooler 12. On the left-hand side, click the Component #1 Details.Set the Data Source to HTFS Databank (NEL40).On the NEL40 Databank drop down menu, select Water as the fluid.Close the window.Before running it is important to save the dataset.This is achieved from the menu bar by selecting File-Save As.Now you can run by clicking on the Run icon or selecting Run-Calculate All from the menu bar.The Status bar in the Run ACOL box should indicate ACOL 5 Successfully Completed.If there is a message indicating a fatal error, then check either the Lineprinter or Error log, which may be found by selecting Output on themenu bar.Edit the dataset accordingly, save and then re-run.The same data may be entered by the API Input form, which is found under Input in the main menu bar.Items indicated by blue are input items used by ACOL, which you can revise.Save your case!Workshop Module 1 - 9Simulate a Water CoolerModule 1 - 9ResultsView the outputs by selecting Output from the menu bar.The Summary-Process box contains the flowrates, temperatures and pressures for the tube and X-side.You should notice that the tubeside exit temperature is 54C (129F), whereas a value of 56C (133F) was expected.Thus the exchanger can perform a greater duty than originally expected.The Summary-Performance box contains information on the heat load, overall heat transfer coefficients and the mean effective temperature difference.Also, a duty ratio is indicated, where a value of 1.06 indicates that the exchanger can achieve a duty of 6% greater than that originally specified.Module 1 - 10WorkshopModule 1 - 10 Simulate a Water Cooler Module 2 - 1Simulate a CondenserModule 2 - 1Module 2 - Simulate a CondenserModule 2 - 2WorkshopModule 2 - 2 Simulate a Condenser WorkshopThe purpose of this module is to simulate a condenser to determine the tubeside outlet temperature for a forced-draught air-cooled heat exchanger that is operating at an altitude of 330 ft..Learning ObjectivesOnce you have completed this section you will be able to: Enter physical properties using the property tableWorkshop Module 2 - 3Simulate a CondenserModule 2 - 3Process OverviewDetails of the process data and some basic geometric data are shown in the following tables:Geometric specificationsItem Value UnitsNo. of bays / unit 4Bundles / bay 2No. fans / bay 2Type of header PlugInlet nozzles 2Outlet nozzles 1Inside diameter of inlet nozzles 8 InchInside diameter of outlet nozzles 6 InchEffective tube length 351 InchTotal tube length 354 InchTransverse pitch 2.44 InchLongitudinal pitch 2.11 InchTube inside diameter 0.766 InchTube outside diameter 0.984 InchFin type L finFin root diameter 1.02 InchFin frequency 11 /InchFin tip diameter 2.25 InchMean fin thickness 0.0157 InchModule 2 - 4WorkshopModule 2 - 4 Simulate a Condenser Bundle details Tubes:408 Rows:6 Passes:3 Rows Pass:2Process dataItem Tubeside X-side UnitsTotal mass flow 356420 5672465 lb/hInlet temperature 155 91.4 FEst. outlet temperature 122 FInlet pressure 23.35 psiaPressure drop 4 psiFouling factor .00156 h ft2 F/BtuWorkshop Module 2 - 5Simulate a CondenserModule 2 - 5Property dataProperty Value UnitMolecular weight 80.1Liquid temperature 155 122 FLiquid density 38.39 40 lb/ft3Liquid specific heat 0.554 0.554 Btu/lb FLiquid viscosity 0.215 0.2 cPLiquid conductivity 0.0719 0.0719 Btu/h ft FEnthalpy/Quality Temp 155 122 FHeat load 5.4366x1070 Btu/hQuality 1 0Vapour temperature 155 122 FVapour density 0.346 0.32 lb/ft3Vapour specific heat 0.455 0.455 Btu/lb FVapour viscosity 0.008 0.006 cPVapour conductivity 0.0114 0.0114 Btu/h ft FModule 2 - 6WorkshopModule 2 - 6 Simulate a Condenser Building the Simulation1. Set the calculation required to Simulation mode for the tubeside outlet temperature.Select Input-Simulation -Tubeside Outlet Temperature.The type of calculation being performed is indicated in the top right hand corner of the process diagram, which also will summarize the process conditions for the tube and air side as the simulation is built.2. From the table given at the beginning of this module, enter the geometric data in British units.If information is not supplied, default values used by the program may be assumed. 3. On the Bundle Specification tab, enter the details of the number of tubes and passes for the bundle as shown: 4. Enter the remaining geometric data and the process conditions for the tubeside (ensuring that you have the correct unit system). For the tubeside fouling, select Constant Rf in item 240.2 andenter the fouling resistance.5. Enter the process data for the X-side.6. Enter the physical property data on the tubeside.The Stream Phase is two-phase.Workshop Module 2 - 7Simulate a CondenserModule 2 - 7As we have been supplied with heat load information for the heat release curve, the Flowrate for the stream must be set to ensurethe property table will accept the heat load information.Enter this data as shown:Module 2 - 8WorkshopModule 2 - 8 Simulate a Condenser Enter the property information for the liquid/vapour phases and the heat release curve as shown:Save your dataset and run.Save your case!Workshop Module 2 - 9Simulate a CondenserModule 2 - 9Exercise 1 - Bundle Set-up and Heat Load DistributionPart of an input file for a three-pass condenser is given in file EX01.A5I. Complete the lines, which specify the bundle arrangement if there are 280 tubes and 7 rows. Pass 3 occupies the first row crossed by the air, Pass 2 occupies rows 2 to 4 and Pass 1 rows 5 to 7.Simulate the performance of the unit. Check the distribution of heat load in desuperheating, condensing and subcooling sections. Exercise 2 - Tubeside Fouling1. Determine the effect of fouling on the performance of the above unit using the following data:2. Test the affect of entering a constant fouling resistance of 0.00035 h m2 C/kcal.How can this design be improved? __________PhaseFouling resistance, h m2 C/kcal (based on tube I/D)Liquid 0.00023Two-phase 0.00035Vapour 0.00047Module 2 - 10WorkshopModule 2 - 10 Simulate a Condenser Exercise 3 - Fan Configuration and Tube Geometry Run the data in file EX03.A5I and compare: Forced and induced draught configuration Plain tubes and G-finned tubes. Exercise 4 - X-side FlowrateRun the data in EX04.A5I and check the predicted tubeside outlet temperature. Determine the air flowrate required to produce the specified tubeside outlet temperature of 40 C.Exercise 5 - Natural Convection and X-side Fouling1. Determine the air flowrate that is required to perform the duty using the exchanger given in EX05.A5I at a summer design ambient temperature of 23C. Assume that there is a constant tubeside fouling resistance of 0.00034 m2K/W.This exchanger experiences total fan failure and the air flowrate produced by natural convection is 1000 kg/hr. 2. Determine the process flow rate that could be handled to give the same outlet conditions.3. Examine the performance of this unit (i.e. with full air flow) if the tubes are exposed to a dirty air stream with a constant dirt film thickness of 1.0 mm.Note the change in X-side pressure drop, and assume the thermal conductivity of the foulant to be 1 W/m K.What is the advantage of using finned tubes in this case? __________Module 3 - 1Design a Steam CondenserModule 3 - 1Module 3 - Design a Steam CondenserModule 3 - 2WorkshopModule 3 - 2 Design a Steam Condenser WorkshopThe purpose of this module is to design a steam condenser with 4 tube rows.Learning ObjectivesOnce you have completed this section you will be able to: Use the design optionWorkshop Module 3 - 3Design a Steam CondenserModule 3 - 3Process OverviewThe task is to produce a design of a steam condenser with 4 tube rows which will have an X-side pressure drop of 120 Pa (~ 0.5 in H2O).The tube and fin details are supplied below.The total tubeside flowrate is 30 000 kg/hr , the inlet pressure and temperature are 1.0 bar and 120C respectively, with an outlet temperature of 50C.The steam will have 5% air present.The ambient air inlet temperature is 20C.Select a design with a maximum tube length of 20 meters and a maximum of 4 passes.The maximum allowable pressure drop through the tubes (excluding nozzles) is 0.2 bar and the inlet velocity will be between 30 and 60 m/s.Tube and Fin detailsItem Value UnitsTransverse pitch 60.3 mmTube layout angle (TEMA) 30 degTube inside diameter 19.9 mmTube outside diameter 25.4 mmTube material Mild SteelType of fin ExtrudedFin root diameter 26.7 mmFin frequency 440 /mFin tip diameter 57.2 mmMean fin thickness .28 mmFin material AluminiumModule 3 - 4WorkshopModule 3 - 4 Design a Steam Condenser Building the Simulation1. SelectInput-Design from the menu bar.2. In the Bundle Design Parameter tab, enter the maximum and minimum tube length, and the number of passes as shown:3. Next, enter the physical property data for the tubeside.Enter the Data Input Method to Calculate From Components.Set the number of components to 2.4. Select Component #1 details, and choose water (two-phase) from the NEL40 databank.5. Choose Component #2 details, and select air.However,set the component phase to a single-phase vapour only (Note: air is anon-condensable).6. Enter the process data for the tubeside, where for the Compositions 1-6, component 1 flow fraction is set at 95% (water) and component 2 flow fraction set at 5% (air).7. Enter the process data for the X-side.In the Design Performance Parameters tab, enter the X-side bundle maximum allowable pressure drop for the tubeside, and the maximum and minimum tubeside velocities as shown:Workshop Module 3 - 5Design a Steam CondenserModule 3 - 5Saveyour dataset, but continue with the following steps before running.ACOL will perform some initial calculations before displaying the Design Data Input screen, where the following values may be entered:Save your case!Module 3 - 6WorkshopModule 3 - 6 Design a Steam Condenser A graphical representation of feasible designs will appear.Here, you can click anywhere within the feasible design area.Some of the basic design information will appear in the output portion of the screen on the left-hand side. To optimise the design you may alter the number of passes (between1-4).When a satisfactory design has been achieved, by clicking on the Simulation button the geometric data will be transferred to a Simulation file type.Save your case!Module 4 - 1Design a Vapour CoolerModule 4 - 1Module 4 - Design a Vapour CoolerModule 4 - 2WorkshopModule 4 - 2 Design a Vapour Cooler WorkshopThe purpose of this module is to design a vapour cooler with 4 tube rows.Learning ObjectivesOnce you have completed this section you will be able to: Use the property table Workshop Module 4 - 3Design a Vapour CoolerModule 4 - 3Process OverviewThe task is to produce a design for a vapour cooler (operating at an altitude of 55 ft) with 4 tube rows.Each will have an X-side pressure drop of 0.25 in H2O.The tube and fin details are supplied below.The total tubeside flowrate is 750 000 lb/hr, the inlet pressure and temperature is 1000 psia and 244F respectively, and the outlet temperature is 130F.The ambient air inlet temperature is 115F.Select a design with a maximum tube length of 480 inches and a maximum of 4 passes.The maximum allowable pressure drop through the tubes (excluding nozzles) is 10 psi and the inlet velocity will be between 10 and 100 ft/s.The tubeside fouling resistance is 0.002 h ft2 F/Btu.Tube and Fin detailsItem Value UnitsTransverse pitch 2.5 InchTube layout angle (TEMA) 30 degTube inside diameter 0.834 InchTube outside diameter 1 InchTube material Mild SteelType of fin G finFin root diameter 1 InchFin frequency 11 /InchFin tip diameter 2.25 InchMean fin thickness 0.018 InchFin material AluminiumModule 4 - 4WorkshopModule 4 - 4 Design a Vapour Cooler Tubeside Vapour property dataBuilding the Simulation1. Set the calculation required to Design.2. On the Bundle Design Parameter tab, enter the maximum and minimum tube length and number of passes.3. Enter the Data Input Method to Enter Stream Data.Ensure that the Data Source is set to Input Directly, and that the Stream Phase is set to Single Phase Vapour Only.Property Value UnitsTemperature 130 244 FDensity 4.9 3.5 lb/ft3Specific heat capacity0.665 0.622 Btu/lb FViscosity 0.014 0.016 cPThermal Conductivity0.022 0.026 Btu/h ft FWorkshop Module 4 - 5Design a Vapour CoolerModule 4 - 54. Click onto the Property Table button and enter the data for the single-phase vapour, as shown:5. Enter the process data for the tubeside.6. Enter the process data for the X-side.On the Design Performance Parameters tab, enter the X-side bundle maximum allowable pressure drop for the tubeside.Also, enter the maximum and minimum tubeside velocity.Module 4 - 6WorkshopModule 4 - 6 Design a Vapour Cooler ACOL will perform some initial calculations before displaying the Design Data Input screen, where the following values may be entered:Save and run your dataset.Save your case!