Introduction To Heat Exchangers

A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT

Faculty
Y Rama Sudhakar
PNM-CG
Prepared by
Production-CG Team
CONTENTS
Heat exchanger
Mechanism of heat transfer
Heat exchangers - Different types
Pattern of flow
Stream allocation
Components of Shell and tube exchangers
Monitoring operation
Startup & Shutdown Procedures

INTRODUCTION TO HEAT EXCHAGNERS
Heat exchanger
Equipment used for transferring heat energy from one medium to
another

Mechanism of heat transfer
Conduction : Without visible movement of matter
Convection : By stream which are in motion
Radiation: Heat transfer by electro magnetic waves in space

Heat transfer in Heat exchangers is due to Conduction and convection
3 Methods of Heat Transfer.mp4

HEAT EXCHANGER TYPES
Heat exchanger types
Double pipe heat exchangers
Plate heat exchangers
Spiral tube heat exchangers
Air coolers
Shell and tube heat exchanger
Fixed tube sheet
U tube bundle
Floating head

Shell and tube exchanger Components
Shell, Tubes, Tie-rods, Baffles, Channel cover, Channel, Pass partition,
Tube sheet, Impingement plate, Nozzles
Shell & Tube Type Heat Exchanger.mp4
SHELL AND TUBE HEAT EXCHANGER NEN-TYPE (re-upload).mp4
HEAT EXCHANGER - TYPES

Double pipe heat exchangers
Simple design and flow distribution
Consists two concentric pipes
Easy maintenance
Easy cleaning by dissembling
Suitable for high pressure service
Uses for small capacity application
Uses where required heat transfer area is less
Stacks of double pipe exchangers are in use

Plate heat exchangers
Exchangers are made of thin plates
High heat transfer area
Easy maintenance
Fluid passes through alternative plates
Not suitable for high pressure and temperatures
Gasketed, Brazen and welded exchangers are in use
Prone to leaking of gaskets

Spiral heat exchangers
Spirally wound coils fitted in a shell
Heat transfer is good due to improved area
Fouling is less
Cleaning is not possible

Air coolers
Heat removal by air
Uses when large quantity of heat removal is
required
More cost efficient
Air is not corrosive
Less load in cooling towers
Low maintenance and operating cost
Suited for cooling high temperature fluids (>80
deg C)
AIR COOLER HEAT EXCHANGER - ANIMATED ASSEMBLY.mp4
HEAT EXCHANGER SHELL & TUBE
Shell and tube heat exchangers

Used for various applications

Uses for heat transfer with and without phase change

Uses for variety of operating conditions

Handles severe fouling

Works where no other exchangers would work

Uses for high viscous fluids

Easy to construct and maintain

Flexibility in MOC, Design and expertise
Three common types of exchangers are
U-tube exchangers
Fixed tube sheet exchangers
Floating head type heat exchangers

U-tube exchangers
Removable type tube bundles
Low cost exchangers
Cleaning is very difficult
Thermal expansion is possible, handles thermal stresses
HEAT EXCHANGER - TYPESNERS
U-tube exchangers
Fixed tube sheet exchangers
Construction is simple
Low cost exchangers
Differential expansion not possible
Cleaning outside of tubes is not
possible
Can be used when inlet temperature
difference is low

Floating head exchangers
Removable type tube bundle
Permits thermal expansion
Internal and external cleaning f tubes
possible
High cost involved

Single pass exchanger
One fluid passes against other
fluid only once

Multi pass exchanger
One fluid passes against other
fluid more than once
FLOW PATTERN
Different flow patterns in use are
Counter current flow
Fluids flow in opposite direction

Co-current flow
Fluids flow in same direction

Cross flow
Fluids flow in direction normal to each other

Split flow
Fluid enters at centre of shell splits and travels along with tubes and
takes turn and join before exiting from the centre

Divided flow
Fluid enters from one point and after splitting flow separately and
exits from two nozzles
FLOW PATTERN
Counter current flow
o Superior to other flow arrangement
o Most efficient flow arrangement

Co-Current flow
o High Thermal stress at one end
o Lowest wall temperature is higher
o When want to avoid condensation

Split flow exchanger

Divided flow in Exchanger

HEAT EXCHANGER - COMPONENTS
Basic components of shell and tube heat exchangers are
Baffles
Tube sheet Tube bundle
Pass partition plates Tube pass Twisted tubes
Baffles
Supports the tube and maintain tube spacing
Increases shell side velocity and Induces turbulence
Improves heat transfer
Different types are baffles are in use

Tie Rod
Supports baffles, holds the baffle assembly and maintain selected
baffle spacing

Tubes
Seamless and welded tubes are available
Finned and twisted tubes uses for increasing heat transfer
Sizing of tubes considers cleaning, pressure drop
Channel heads
Contains the tube side fluid and provide desired flow path

Tube sheet
Plate where tubes are inserted
Tubes shall be appropriately secured to the tube sheet
Holes in the tube sheet drilled in triangular and rectangular shapes
Triangular pitch provided compactness and more heat transfer
Rectangular pitch provided easiness in cleaning

Impingement plate
Plate provides at entry of low path to minimize impingement

Heat exchangers principles - Complete video.mp4
Building Heat Exchangers.mp4
SHELL & TUBE HEAT EXCHAGNER
The more heat that can be exchanged between process streams, the smaller
will be the fuel consumption and the __________ will be the cooling towers
required.

The use of baffles will __________ the heat transfer rate.
lower
increase
FIXED TUBE SHEET EXCHAGNER
Because there is no provision for expansion, the fixed tube sheet exchanger
would be unsuitable for uses in which the temperature difference between
the shell-side and the tube-side fluids was very _________.

In this type of exchanger, it is impossible to clean the outsides of the tubes.
Thus, it would be suitable for use only with a clean, non-fouling ________
side fluid.
large
shell
FLOATING TUBE SHEET EXCHAGNER
The tube sheet is fixed at only one end. The other end is free to move to
allow for __________ of the ___________.

Thus, the floating tube sheet exchanger can be used when the temperature
difference between the two fluids is ___________.
great
expansion tubes
U TUBE EXCHAGNER
U-Tube exchanger is often used when there is a large ____________
____________ between the shell-side and the tube-side fluids.

U-Tube exchangers are used in situations where the ________ side fluid is
clean.
tube
temperature
difference
Which of the three exchangers would be best for use when the shell-side
fluid had a temperature much higher than the tube-side fluid:
single pass, fixed tube sheet exchanger
U-tube exchanger
three pass, fixed tube sheet exchanger

Which of the exchangers make allowances for the expansion of the tubes?
U-tube exchanger
single pass, fixed tube sheet exchanger
floating tube sheet exchanger
multi pass, fixed tube sheet exchanger

In Floating tube sheet exchanger, tube bundle can be readily removed for
cleaning outside surfaces of the tubes. So this type of exchanger can be used
when both the fluids are _________ and ____________.
dirty fouling
By using multi-pass exchangers, the effective length of flow is increased and
higher flow velocities are possible. The greatest heat transfer rate would be
possible in the exchanger with:
single pass on shell and tube side
single pass on the shell side and double pass on the tube side
double pass on the shell and tube side

The three basic types of shell-and-tube heat exchangers are:
the __________ tube sheet type with no provision for tube expansion
the ______________ exchanger in which the tube bends to allow for
expansion
the ___________ tube sheet type in which the tube sheet is fixed at
one end.

If the temperature difference between the shell-side fluid and the tube-side
fluid is quite large, then either the ___________ tube sheet exchanger or the
____________ tube exchanger should be used.
fixed
U-tube
floating
floating
U-tube
BAFFLES
Baffles can be used on the shell-side of any of the basic types of exchangers.
By increasing flow velocity and turbulence, baffles will ___________ heat
transfer rate.

There are two general types of baffles used on the shell-side:
Transverse (crosswise) baffles are used to create ____________ flow
To make the exchanger multi-pass on the shell-side __________
baffles are used

By increasing the velocity and turbulence of flow on the shell-side, baffles
increase the rate of _______________ between the two fluids.

The half-moon baffle is suitable for use with fouling fluids or for large
volumes of flow. The purpose of half-moon baffles is to ___________ the
flow turbulence.
increase
increase
turbulent
longitudinal
heat transfer
BAFFLES
The three general types of baffles shown are:
the half-moon (low pressure drop)
the disk-and-ring (low pressure drop)
the orifice type (high pressure drop)

Which of the three types would not be suitable for a heavy fluid with a high
flow volume? ___________
orifice
TUBE ARRANGEMENT - PITCH
In the first configuration (A), the tubes are set in a square pattern. This is
called _________ ___________.
In the second configuration (B), the tubes are set in a triangular pattern.
This is called ____________ __________.

Thus, with dirty, scale-forming fluids, ____________ pitch must be used,
even though the best arrangements for greatest heat transfer rate would be
_____________ pitch.

A third configuration of tubes is the diagonal square (C). Diagonal square
pitch is similar to square pitch. The tube bundle __________ be mechanically
cleaned.
can
square pitch
triangular pitch
square
triangular
TUBE ARRANGEMENT - PITCH
_____________ pitch configuration would result in the highest heat transfer
rate.

For a dirty, fouling fluid in which the temperature difference was quite
large, the best heat exchanger to use would be:
the fixed tube sheet exchanger
floating head exchanger
Triangular
HEAT EXCHANGE EQUIPMENT GENERAL PROPERTIES
In ordinary shell-and-tube exchangers, the more ___________ fluid is
usually sent through the shell where the baffles will set up __________ flow.
In this way the viscous fluid will flow more __________ and the rate of heat
transfer will ____________.

If one of the fluids in the exchanger is a gas it will be sent through the shell-
side of the exchanger , as in a reboiler or a condenser.
If the exchanger is used as a reboiler, the liquid is vaporized in the ________
side.
If vapor is cooled and liquified in the shell-side of the exchanger, the
exchanger is called a _______________________.

In general, the tube material should be the one with the __________
thermal conductivity (but limited by others factors such as cost, corrosion,
and temperature).
rapidly
viscous
turbulent
shell
increase
Condenser (or reboiler)
highest
HEAT EXCHANGE EQUIPMENT GENERAL PROPERTIES
Some of the more common tube materials are carbon steel, stainless steel,
aluminium, admiralty, copper-nickel alloy, and brass. If only thermal
conductivity had to be considered in selecting a tube material, which metal
would be the best? __________

A larger area is obtained by using a greater number of the smaller diameter
tubes, but since small tubes offer more resistance to flow, the pressure drop
will be ___________ in smaller tubes.

So the ideal tube size for a give service will be the size that offers easy
cleaning and ____________ surface area for ___________ pressure drop.
greater
maximum smallest
copper
ALLOCATION OF STREAMS
Allocation of streams based on
Fouling
Fluid with high fouling factor in tubes for ease in maintenance
Increased velocity in tubes reduces fouling
Increases exchangers life
Pressure
High pressure stream in tubes
Allocation in tube side reduces the thickness of shell
Corrosion
Fluid with high corrosiveness in tube side
Less expensive, easy maintenance
Viscosity
Fluid with high viscosity in shell side for better heat transfer
Phase change
Fluid with phase change will be in shell side
MONITORING OF EXCHANGERS
Fouling
During the operation salts, algae deposits on he surface of metal
Deposition increases with time
Reduces heat transfer, flow rate and increases pressure drop
Deposited layer has maximum thermal resistance
Higher pressure drop demands higher pumping costs
Types of fouling are
Precipitation fouling
Particulate fouling
Chemical reaction fouling
Corrosion fouling
Solidification fouling
Biological fouling
Exchanger Tube Fouling and Pitting.mp4
Precipitation fouling
Due to crystallization of salts, oxides and hydroxides from solutions
Particulate fouling
Particles suspended in water deposits due to flocculation and
coagulation
Chemical reaction fouling
Fouling occur due to chemical reaction in fluids. Ex: Polymerization,
carbonization
Corrosion fouling
Fouling occur due to corrosion of material. Ex: Oxidation
Solidification fouling
When a component solidifies due to sub cooling. Ex: Deposition of
wax
Biological fouling
Undesirable accumulation of micro organisms
Fouling control
Pre filtration of cooling water
Water treatment (Membrane separation, Ion exchange methods)
Controlling PH. (Ex: Alkylation)
Removal of dissolved oxygen
Using corrosion inhibitors
Using chemical fouling inhibitors
By maintaining uniform velocity
By eliminating stagnant regions
Back flushing
Blow-down
Fouling monitoring systems are in place
Heat Exchanger Removal & Cleaning.mp4
Operation of heat exchangers
Always operate under design conditions
While taking in operation, first open vent and establish cold side
circulation
Commission hot side by opening vent after commissioning cold side
Avoid Thermal shocks while commissioning and during operation
Take exchanger in line slowly
Flow fluctuations shall be avoided to prevent vibrations
Monitor P, T across exchanger with time
Prevent hammering in exchangers by removing condensate
Drain the hot stream completely first and cold stream next for
shutdown
Monitor the quality of cooling water regularly to minimize fouling
Follow Standard procedures for operation, isolation, Handing over
and taking over of exchangers
What can go wrong
Improper line-up of exchanger
Un manned draining
Lining-up hot side without lining-up cold side
Isolation of TSV, PSVS
Sudden line-up of exchanger leading trip, fires and leaks
Continuing operation of leaking exchangers

Improper utilization of exchanger
Opening of exchanger bypass valves
Exchangers inline with high pressure drop
Exchangers operation outside design conditions
Lower tube and shell side velocities

Improper isolation of exchangers
isolation of exchanger without draining
Isolation of exchanger without flushing
Handing over of exchanger without blinding

HEAT EXCHANGERS - STARTUP
HEAT EXCHANGERS - SHUTDOWN
HEAT EXCHANGERS HANDING OVER PROCEDURE
HEAT EXCHANGERS TAKING OVER PROCEDURE
QUERIES
1. Industrial heat transfer is due to ----------------------mechanism of heat transfer
2. Most common type of heat exchangers in refinery are -------------------------------
3. Fixed tube heat exchangers are used where temperature difference is ----------------------
4. The use of baffles will __________ the heat transfer rate
5. Flow pattern in air fin coolers are --------------------------------
6. Fluid with high corrosiveness placed in -----------------------side of exchanger

Introduction To Heat Exchangers

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A Sunrise Project for a Sunshine Future

PARADEEP REFINERY PROJECT

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