Make better heat exchanger design decisions with Exchanger Optimizer 3.0

Robert Browning, Principal Engineer, Software Development

Exchanger Optimizer helps engineers solve different types of design problems. Enabling specification of more accurate design details, Exchanger Optimizer 3.0 features more robust analysis of complicated geometries. For example, fixed tubesheet heat exchangers are often designed with expansion joints to handle the differential thermal growth between the tubes and the shell. 

Exchanger Optimizer 3.0 is available for download.

Key enhancements in Version 3.0

Expanded shell-and-tube heat exchanger design capabilities

  • ASME code calculations for tube internal/external pressure (Figure 1)
  • ASME code calculations for UHX fixed tubesheet (Figure 2, Figure 3, and Figure 4)
  • Options for bellows (thin wall) shell expansion joint and tail pipe bellows for single-pass floating heads
  • Improved cost estimate methods for Inconel® and stainless steel bellows
  • Flanged and flued (thick wall) spring rate calculations based on TEMA 8
  • Improved nozzle design logic, adding support for self-reinforced nozzle types (e.g., long weld neck, heavy barrel, and equal barrel nozzles)
  • More rigorous costing methods for plate and nozzle forgings

Additional mechanical design considerations 

  • Tube-to-tubesheet joint mockup
  • Heat treatment for U-bends
  • Separate material markup factors for carbon steel, low alloys, and high alloys
  • Furnace and local heat treatment methods 
  • New options to customize cladding and weld overlays
  • Specification of the lining type (weld overlay or bonded clad) and the required thickness on the lining options window (Figure 5)
  • Improved accuracy of fabrication activities
  • Grouping of fabrication activities (Figure 6) by category, with subtotal of labor hours 
  • Shell-and-tube mechanical Fabrication Schedule (Figure 7)

Improved heat exchanger installation options

  • Vertical heat exchanger foundation and structure estimation methods
  • New installation items, including heat exchanger shop inspection
  • Fields to customize the rates for insurance, taxes, contingencies, engineering labor rates, construction overhead, etc.
  • User-defined installation items

New shop locations

  • Spain
  • China—domestic and export
  • Mexico


Exchanger Optimizer Tube Calculations
Figure 1. On the Tube Calculations input panel, specify tube properties and view the code calculation results.

Exchanger Optimizer Fixed Tubesheet Calculation Results
Figure 2. Use the Fixed Tubesheet Calculation Results panel to quickly identify deficiencies in the design.

Exchanger Optimizer Fixed Tubesheet Operating Conditions
Figure 3. Specify operating conditions, including mean metal temperatures for the
tubes and shell, in the Fixed Tubesheet Operating Conditions panel.

Exchanger Optimizer Fixed Tubesheet Options
Figure 4. Reduce loads on the tubes due to differential growth between the tubes and shell by providing
details on expansion joints—flanged and flued or bellows type—in the Fixed Tubesheet Options panel.

Exchanger Optimizer Lining Options
Figure 5. Specify the lining type (weld overlay or bonded clad) and the required thickness on the Lining Options panel.

Exchanger Otpimizer Fabrication Activities
Figure 6. View fabrication activities by category, including a subtotal of labor hours.

Exchanger Optimizer Fabrication Schedule
Figure 7. See your process from start to finish with the new shell-and-tube mechanical Fabrication Schedule.