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Overview of HTRI’s Stream Analysis Method

May 11, 2026

Brandon White, Engineer, Experimental Research In 1958, Tinker introduced the concept of treating shellside flow in baffled shell‑and‑tube exchangers as a network of hydraulic resistances, analogous to electrical resistors. Each flow path—or stream—was assigned a resistance that depended on its location and geometry, providing a systematic way to predict pressure drops...
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• STREAM ANALYSIS METHOD
• SHELL-AND-TUBE
• HEAT EXCHANGERS
• BAFFLE

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Discover the enhanced power and innovative features of HTRI SmartPM™ 6.0

January 12, 2026

HTRI's innovative digital transformation (DX) software, SmartPM, continues to revolutionize performance monitoring and prediction of many complex and often heavily fouled networks of heat exchangers and fired heaters. Users enthusiastically suggest improvements, and HTRI implements many of them. These include new capabilities to extend the range of heat exchanger networks that...
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• XJPE
• XHPE
• XSPE
• XPHE
• XIST
• XCHANGER SUITE
• XACE
• TUBE INSERT
• SMARTPM
• SHELL-AND-TUBE
• HEAT EXCHANGERS
• HEAT EXCHANGER DESIGN
• EXCHANGER OPTIMIZER
• BAFFLE
• AIR COOLER

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S-SS-3-30 Predictions of Single-phase Flow in TEMA F-shell Heat Exchanger: CFD vs. Xist

December 21, 2022

This report compares computational fluid dynamics (CFD) and Xist predictions of single-phase performance in a TEMA F-shell heat exchanger with a sealed longitudinal baffle. In the initial comparison, CFD underpredicted both duty (16% less) and pressure drop (over 50% less). We then represented an F shell in Xist using two E-shell...
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• XIST
• SINGLE-PHASE
• CFD
• BAFFLE

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Baffle design dictates ideal flow

June 11, 2020

Ashley Simmons, Engineer, Technical Support Each heat exchanger has unique requirements due to process constraints, site limitations, or cost concerns. The fundamentals of good design apply to every variety of exchanger. The primary goal of every designer is to optimize exchanger design for the most effective heat transfer possible. One of...
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• XIST
• WEBINAR
• SHELL-AND-TUBE
• BAFFLE

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TT-28 Specifying disk-and-doughnut baffles in Xist

December 04, 2019

Component: Xist Date posted: 5 December 2019 (updated 26 October 2023) Disk-and-doughnut baffles are an alternative to conventional segmental baffles. Figure 1 illustrates a generic disk-and-doughnut baffle configuration. In many industrial units, tubes are present only in the overlap region between the disk baffles and the doughnut baffles—an arrangement that effectively...
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• XIST
• TECHTIP
• NTIW
• BAFFLE

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Educational: Single-segmental Baffle Cut and Spacing

April 25, 2019

This webinar discusses considerations and limitations in the use of single-segmental baffles. It demonstrates the impact of baffle cut and spacing in various process applications....
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• BAFFLE
• EDUCATIONAL

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TT-26 Vibration analysis of nonbaffled H shells

May 14, 2018

Component: Xist, Xvib Date posted: 15 May 2018   TEMA H shells are commonly used as horizontal shellside reboilers. They can be baffled or nonbaffled as long as the unsupported span length remains within TEMA guidelines. In nonbaffled cases, the tubes have three intermediate support plates, located under each nozzle and at...
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• BAFFLE
• TECHTIP
• VIBRATION

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TT-18 Design guidance for no-tube-in-window (NTIW) baffles

January 26, 2017

Component: Xist Date posted: 25 March 2015 Last updated: 16 May 2024 Compared to other segmental baffle designs, no-tube-in-window (NTIW) baffles improve tube support with low pressure drop. Adding intermediate support plates between baffles can alleviate tube vibration for virtually any baffle spacing, thus simplifying low pressure drop designs. However, NTIW...
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• NTIW
• DESIGN
• BAFFLE

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TT-9 Specify double-segmental baffles in Xist

January 26, 2017

Component: Xist Date posted: 19 August 2009 Last updated: 7 August 2025 Double-segmental baffles are TEMA baffles that split the flow along the length of a bundle. The baffle pattern diverts flow with alternating center baffles and wing baffles as shown in Figure 1. Figure 1. Double-segmental baffle configuration Double-segmental baffles...
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• XIST
• TECHTIP
• BAFFLE

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TT-8 Model tube vibration in the bundle entrance region with parallel-cut baffles

January 26, 2017

Component: Xist Date posted: 4 November 2008 Date retired: 7 December 2021 Xvib models the vibration potential of a single tube using a rigorous finite element method. It is the most accurate tool available to estimate the potential for tube damage. Using Xchanger Suite 8, you can quickly complete an Xvib model...
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• BAFFLE
• TUBE LAYOUT
• VIBRATION

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Research Update: Analysis of NTIW Shellside Performance using CFD and Xist

January 16, 2017

This webinar will discuss Xist® and CFD predictions of three NTIW exchanger configurations – 2 baffle, 4 baffles, and 6 baffles. The discussion will focus on the contributions of crossflow and longitudinal flow on heat transfer, which is due to varied baffle spacing for the same baffle cut. During the webinar,...
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• BAFFLE
• CFD
• NTIW
• RESEARCH
• SHELLSIDE
• XIST

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S-SS-3-22 Stream Analysis in a Single-Segmentally Baffled Exchanger: CFD vs. Xist

January 16, 2017

HTRI conducted computational fluid dynamics (CFD) simulations to investigate leakage and bypass stream behavior under various flow regimes in an industrial-scale heat exchanger with single-segmental baffles. To cover a wide range of Reynolds numbers, the simulations tested single-phase water and Alta-Vis oil. Both concentric and eccentric configurations of the exchanger’s tube-to-baffle...
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• XIST
• CFD
• BAFFLE

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Is My Design OK? Baffled by Heat Exchanger Design

January 16, 2017

This webinar examines different types of baffles (TEMA and non-TEMA) and demonstrates how different baffles affect heat exchanger performance. Further, we discuss some rules-of-thumb for proper design with respect to baffle cut, spacing, and orientation. Finally, we will provide a summary of the performance characteristics of the different baffle types, to...
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• BAFFLE
• DESIGN
• RATING MODE
• XIST

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S-SS-3-21 Disk-and-Doughnut Baffled Heat Exchangers: CFD Simulations and Methods

January 16, 2017

Disk-and-doughnut baffled heat exchangers can generate more heat transfer with less pressure drop than conventional segmental exchangers in certain industrial applications. Unfortunately, little information is available on these units in service. This report introduces new methods for analyzing and rating a disk-and-doughnut baffled heat exchanger. Using three-dimensional computational fluid dynamics (CFD)...
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• XIST
• CFD
• BAFFLE

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S-SS-3-19 Improved Pressure Drop Method for Helical Quadrant Baffle Exchangers

January 16, 2017

A shellside helical flow path in a shell-and-tube exchanger can provide a number of distinct advantages over the reversing, serpentine flow path of conventional segmental baffles; however, current open literature prediction methods do not provide the confidence engineers need to make sound design decisions. Several fundamental geometric parameters either are not...
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• SHELLSIDE
• SHELL-AND-TUBE
• CFD
• BAFFLE

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S-SS-3-17 Heat Transfer and Pressure Drop Methods for Square One Baffles

January 16, 2017

TRICO Metal Products, Inc. manufactures Square One™ baffles, a strip baffle or egg crate tube support technology for square pitch layouts. This report documents heat transfer and pressure drop methods for shellside flow using Square One baffles. Based on the existing Xist® window flow model, the methods have been adjusted for...
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• BAFFLE
• CFD
• XIST

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Q7-4 CFD Study of Inlet Zone Performance: Parallel vs. Perpendicular Segmental Baffle Cuts

January 16, 2017

Under contract from HTRI, university researchers simulated the fluid flow and heat transfer characteristics in the inlet zone of a shell-and-tube exchanger using computational fluid dynamics (CFD). Results revealed that the ratio of heat transfer to pressure drop for parallel baffle cut orientation was as low as 71 percent of that...
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• SHELL-AND-TUBE
• CFD
• BAFFLE

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