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White Paper

Jump Start: Aspen Shell & Tube Exchanger V8
A Brief Tutorial and Sample Case for Sizing in EDR Shell & Tube
(supplement to training and online documentation)
Lauren Sittler, Product Management, Aspen Technology, Inc.
Tom Ralston, Director, Equipment Design and Rating, Aspen Technology, Inc.
© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved. 11-3826-0713
Contents
Introduction to Aspen Shell & Tube Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Scope of this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tutorial Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Step 1. Download the Aspen HYSYS File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 2. Create a New EDR Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 3. Import Process Data and Specify Application Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Process and Property Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Application Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 4. Select Appropriate Configuration and Sizing Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Step 5. Save and Run Sizing Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 6. Viewing the Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Appendix A. Navigate the EDR User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Navigation Pane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Text Coloring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
User Input Tabs: Geometry, Process, Errors & Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Appendix B. Alternative Methods to Specify Process & Property Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manually Enter Property Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Searching the Properties Databanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Appendix C. Using a Design Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Introduction to Aspen Shell & Tube Exchanger
Aspen Exchanger Design & Rating (Aspen EDR) software provides the most comprehensive package available for
designing and rating heat exchangers. EDR software is used daily for thermal, mechanical and process engineering by
engineering contractors, process operators and exchanger fabricators throughout the world. Aspen Shell & Tube
Exchanger can be used to design all major industrial shell & tube exchanger equipment types in any combination of
processes including single phase heating or cooling and boiling or condensation. Typically, users save between 10-30% on
equipment cost by effectively designing their exchangers using Aspen EDR.
Given a process requirement and physical property data, the program conducts a comprehensive design search to find the
optimum cost arrangement capable of satisfying the process constraints. The program provides detailed exchanger
geometry and performance details as well as a specification sheet, setting plan, and tube layout drawings.
Completed designs can be transferred to Aspen Shell & Tube Mechanical for complete mechanical design to the
requirements of ASME or other leading international design codes.
Scope of this Document
This tutorial is intended as a guide to getting started using Aspen Shell & Tube Exchanger to create, evaluate, and save
designs. It offers a step-by-step explanation of how an equipment designer would use the standalone program.
Instructions on how to import process and property data from Aspen HYSYS® and Aspen Plus® are included but, for
simplicity, the new automatic workflows for exchanger sizing provided in V8 simulators are covered in separate
documents. The new workflows are invaluable to the process engineer conducting preliminary design of heat exchangers
and as part of process revamp studies.
Additional resources for a more comprehensive understanding can be found at:
• The AspenTech website
• The AspenTech support site
• AspenTech business consultants
See the Additional Resources section of this document (page 11) for more detail. The files associated with this example are
available for download on the Customer Support & Training Website.
Tutorial Overview
We will demonstrate the workflow by completing the design of a Shell & Tube exchanger for a crude preheat train process.
We will import process and property data from an Aspen HYSYS case to size the exchanger. Explanations for each step
will be provided. The appendix provides additional details on each step, as well as instructions for alternative methods of
completing a step. Figure 1 shows the Aspen HYSYS process flow diagram; we are interested in Exchanger e304.
1
Figure 1. Exchanger e304 in Aspen HYSYS Preheat Train
Step 1. Download the Aspen HYSYS File
Download the file Preheat Train for Jump Start EDR.hsc, and save it on your desktop. We will import data from this file
later so remember the location.
Step 2. Create a New EDR Case
On your desktop, open the Start Menu > All Programs > Aspentech > Exchanger Design and Rating V8.0 > Exchanger
Design and Rating User Interface.
When EDR opens, click on the File menu > New > Shell & Tube Exchanger (Shell&Tube) > OK (Figure 2).
Figure 2. Open Aspen EDR Shell & Tube
2
The EDR Shell & Tube program will open in the Interactive Design Console. You will see that some default parameters have
already been specified and that some input is still required. Appendix A explains the EDR user interface. Take a minute to
familiarize yourself with the navigation and the meanings of symbols, text coloring, etc.
Step 3. Import Process Data and Specify Application Options
Process and Property Data
Process and property data can be entered in three ways: (1) manually, (2) by using the physical property databanks
provided within the program, or (3) by importing from a simulation case. In this tutorial we will use the 3rd option and
import data from an Aspen HYSYS case file. The alternative methods are explained in Appendix B.
Import data from Aspen HYSYS
Click on the File menu > Import From > Aspen HYSYS V8.0. In the file browser locate the file Preheat Train for Jump Start
EDR.hsc and click Open. From the Exchanger List choose e304 and click OK (Figure 3).
Figure 3. Select Exchanger e304 in the Aspen HYSYS Case
3
Another dialogue box “Import PSF data” will appear. Click OK again to import the case data. Now you can see that our
Input folder is fully specified, all red incomplete marks have disappeared.
To better model the real process conditions let’s adjust the fouling resistance of our streams. Open the Process Data form.
This can be found in the Console Process tab or Input > Problem Definition > Process Data. Set the following.
Fouling Resistance
Hot Stream
Cold Stream
0.002 hF/BTU
0.001 hF/BTU
Application Options
Let’s set the application options for this example.
From the navigation pane, expand the Problem Definition folder and open the Application Options form. Click on Input >
Problem Definition > Application Options. Figure 4 shows the desired specifications.
Figure 4. Set Application Options
4
Location of hot fluid
Shell side
Select geometry
SI
Step 4. Select Appropriate Configuration and Sizing Constraints
Click on the Console from the navigation pane. Our exchanger general geometric constraints have been fully specified
with default values. We are going to change some of them to get a more appropriate design for our process. Since this
exchanger is used in a crude application, we are going to change the TEMA type to a one pass shell with a removable
cover and floating head with backing device, and set the tube pattern to 90 square. These selections allow for disassembly
and cleaning of the unit (Figure 5).
TEMA Type
AES
Hot Side
Shell side
Tube Pattern
90-Square
Figure 5. Set Configuration Options
5
Step 5. Save and Run Sizing Optimization
Now that required input is complete, save the case. Run the sizing (full Shell & Tube design optimization logic) by clicking
the Run button on the Console. A Program Status window will appear showing the designs being evaluated. When the run
is complete, close the window. We can see that there are a couple of warnings with this design, but no errors.
Step 6. Viewing the Results
Open the design Console from the navigation pane. On the Geometry tab we can see the setting plan, tube layout, and
stream temperature profiles. We can also see basic geometry data such as the number of shells and tubes and the
dimensions of both.
For this design, we have 2 shells in series with 2 tube passes and 26 baffles. Our oversurface % is 2 and our pressure drop
ratio is 0.88\0.48. The overall cost is $212,656 (Figure 6).
If we change one of the parameters and run the design again, we can see the results of the new design side-by-side with
our first design. This makes it easy to tell whether or not a given change improves the exchanger cost or performance.
Figure 6. Design Console Results
6
Expand the Results folder to see more design specifics including performance calculations, and mechanical drawings for
the setting plan and tubesheet layout (Figure 7).
Figure 7. Results Summary
To compare your results with the expected results of this exchanger sizing, view the solution file EDR Jump Start e304
Solution.
7
Appendix A. Navigate the EDR User Interface
Navigation Pane
The navigation pane provides access to data input and design specifications, program options, and results. All folders
marked with a red X indicate that information is missing and must be specified before the calculation can be run.
Input fields marked in light blue shading must be completed in order to run the case. Note that many of the forms,
including all those in the Exchanger Design folder and the Program Options, folder are automatically populated with
default parameters and will be marked complete upon opening a new design file. It is useful to check that the specified
information in these folders is appropriate for a particular case. All results forms will be greyed-out before the calculation
is run, indicating that results are not yet available.
Text Coloring
Default parameters appear in red. Many of these may be interdependent and you may see them change as you change
other entries and selections. User specified information is always black. Figure 8 shows the Design Console interface.
Figure 8. The Design Console User Interface
8
User Input Tabs: Geometry, Process, Errors & Warnings
Geometry
The Geometry tab contains all user-specified information pertaining to exchanger configuration, shell and tube
dimensions, and the overall results of the simulation after the case is run.
Process
The Process tab contains data regarding the physical conditions of the process streams, pressure drop, and fouling
resistance of the fluids.
Errors & Warnings
Check the Errors & Warnings tab after running the optimization to identify operational and performance risks that were
identified with the design.
Appendix B. Alternative Methods to Specify
Process & Property Data
Manually Enter Property Data
Open the Property Data folder and click on Hot Stream Composition. On the Composition tab, click the down arrow in the
dropdown box next to Physical Property Package. Choose “User Specified properties”. Open Input > Property Data > Hot
Stream Properties. Here you can type in property data for a range of temperatures and pressures or you can Copy/Paste
data from Excel. Repeat for the Cold Stream Composition (Figure 9).
Figure 9. Manually Specify Property Data
9
Searching the Properties Databanks
In the Property Data folder, on the Hot Stream Composition form, click on the dropdown box next to Physical Property
Package and choose one of the databases (Aspen Properties, COMThermo, BJAC). Click the Search Databank button.
Enter the compound name, select the component to add, and click the add button. Repeat until your component list is
complete click ok (Figure 9).
Figure 10. Search for Compounds from the Properties Databank
Appendix C. Using a Design Template
When you open a new case, instead of choosing New, click on the Templates Tab and choose from either the default EDR
design templates or a template saved on your desktop. When the file is opened it will already contain geometry and
design specifications preselected for that exchanger type. You can prepare your own templates to impose company design
standards or process pressure drop or fouling resistance constraints. You need to explicitly save your template files as
“.edt.”
You will typically find the standard design templates provided with your installation in: C:\Program Files
(x86)\AspenTech\Aspen Exchanger Design and Rating V8.0\Data\Template.
10
Additional Resources
Check out other training materials specifically for this product:
Public Website
www.aspentech.com/products/aspen-edr.aspx
www.aspentech.com/products/aspen-tascplus.aspx
Online Training
www.aspentech.com/products/aspen-online-training
Video Tutorials
Autosizing Shell & Tube Exchangers in Aspen HYSYS V8.0
https://www.brainshark.com/aspentech1/autosize-shell-tube-HYSYS
New Interactive Sizing in Aspen Plus
https://www.brainshark.com/aspentech1/edr-integration-aspen-plus
Jump Start Tutorial
Getting Started in Aspen Shell & Tube Exchanger V7.0
Jump Start: Sizing EDR Shell & Tube Exchangers in Aspen Plus
Help Menu
11
About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals,
engineering and construction, and other industries that manufacture and produce products from a
chemical process. With integrated aspenONE® solutions, process manufacturers can implement best
practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the world’s leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
Worldwide Headquarters
Aspen Technology, Inc.
200 Wheeler Road
Burlington, MA 01803
United States
phone: +1–781–221–6400
fax: +1–781–221–6410
[email protected]
Regional Headquarters
Houston, TX | USA
phone: +1–281–584–1000
São Paulo | Brazil
phone: +55–11–3443–6261
Reading | United Kingdom
phone: +44–(0)–1189–226400
Singapore | Republic of Singapore
phone: +65–6395–3900
Manama | Bahrain
phone: +973–17–50–3000
© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen
Technology, Inc. All rights reserved.
11-3826-0713
For a complete list of offices, please visit
www.aspentech.com/locations

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