HEAT EXCHANGERSHEAT EXCHANGERS introduces the learner to the phenomenon of heat transfer as itis applied in modern refining techniques. In Section 1: Heat ‘Transfer, conduction and convection as methods of heat transfer are explained before the more practical matter of heat transfer in tubes is discussed. ‘Section 2: Heat Exchange Equipment first details the various parts of heat exchangers as well as their functions. It then describes the various types of shell and tube heat exchangers. Section 3: Exchanger Operation and Maintenance goes into startup and ‘shutdown procedures and deals with various problems of exchanger main- tenance. Itthen describes the flow and mechanisms of various heat exchange systems.INSTRUCTIONS This isa programed learning course. Programed learning gives information in a series of steps called frames, Each frame gives some information and asks ‘you to make use of it. t, cover the response column at the Here is how it works. right with a mask, Read this frame and use the information it gives to fill in the blank. A micrometer is ‘thousandtths of a instrument he signed to measure in ‘A micrometer is a good tool for measuring very. differences in size. Move the mask down to uncover the word at the right of the frame. If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame, ‘The drawing of a micrometer provides information that will ‘help you fill in the next blanks. oBsect 70 BE MEASURED. anviL SPINDLE ‘Seven major parts are shown in the drawing, but only the _____and the___contact the object. to be measured. small anvil, spindleThe next frame calls for a choice, Circle or underline the ap- propriate word. Of the two parts that contact the object, only the (anvil/ spindle) moves. ‘A program is a series of frames that work like the ones you have just done, Read the frame, Use the information to fill in the blanks or make 2 choice. Move the mask down and check the response column, Go on to the next frame, Remember to cover the response column with a mask before you begin each page. spindleHEAT EXCHANGERS ‘Section 1: Heat Transfer HEAT TRANSFER BY CONDUCTION, Exhibits 1 through 10 are printed in a special pull-out section in the center of this book. Please pull them out now so that you can Freer to them as they are mentioned in the text 1, Heat is a form of energy. Like other forms of eneray, heat can be from one place to another. 2. The process by which heat travels through a substance is called conduction, Thus, the material through which heat passes is called the 8. Suppose a container of hot water is placed next to a con- tainer holding an equal amount of cold water. I¥ the containers are touching, eventually the temperature ) of the cold water (increases / decreases ) 4. And, the temperature of the hot water '5. Heat has been conducted from the container of hot water to the container of cold water, When the water in the two containers reaches the same ‘temperature, heat transfer {stops still continues ) 6, In other words, conduction of heat continues until the heat 's evenly distributed throughout the substance. The final temperature is ( greater than / less than / an average of )the two beginning temperatures. 7. One thing that the rate at which heat is conducted through ‘@ conducting material depends on is the nature of the material ‘Some materials are better than others, moved, or transferred ‘conductor increases decreases an average of conductors8. Copper, for exampla, is a better conductor of heat than cast iron. {A stove made of solid copper conducts heat ( more rapidly ‘more slowly }than one made of cast iron. 9. Suppose equal amounts of heat are applied to a one-inch thick piece of steel and toa two-inch thick piece of steel, It takes longer for heat to pass through the metal in exam- ple (A/B) 10. Suppose two steel rods are heated at one end. Ittakes longer for heat to pass from one end to the other ofrod( A/B ‘more rapidly11, Lookat this drawing of two sets of containers. 16” Fig. Fig.2 In Figure 1, the difference in temperature between con- tainer Aand container 8 is Bs 100° 12, InFigure2, the difference in temperature is ae 150° 18. Conduction takes place at a faster rate in Figure 2 ‘Therefore, the rate of conduction varies with the size of the temperature difference 14, A standard measure of the rate at which conduction takes place is called thermal conductivity. ‘Thermal conductivity takes into account whether the mate- fidlisa__ conductor, the = ‘900d thickness, and — of the conductor, and the amount length ofthe temperature tone difference HEAT TRANSFER BY CONVECTION 16. This drawing represents a room containing a heat source none corner. ‘The air which touches the heat source is heated by id ti conduction16 i 18 19. 20. a1 ‘As the air touching the heat source is heated, it expands ‘and becomes | lighter / heavier } than the.air in the rest of the room. Because itis lighter, the warm air (rises / falls). Cooler air from the floor level moves up and contacts the source 1100 becomes lightar from expansion and { rises / falls } ‘This process is repeated again and again and produces a circular flow pattern. ‘As the air flows around the room itcarries with it ‘As warm and cold gir meet near the center of the room, the circular flow pattern is interrupted and turbulence ‘ccurs, 22 Warm air and cold air are mixed together, and heat. is transferred from the to the all. Convection is heat transfer from one point to another within a liquid or gas by the mixing of one portion with another. Heat is transferred from the heat source to the air by (conduction / convection } and from the warm air to the cold air by ( conduction / convection }. lighter rises heat rises heat ‘warm; cold conduction convectionHEAT TRANSFER THROUGH TUBES, 23. 24. 26. 26. ar. Ii the temperature of a fluid flowing inside a tube is ditfer- tent from the temperature of the atmosphere outside the tube, _______ flows through the tube wall heat ‘The amount of heat that flows depends on the tempera- ture —__ between the fluid and the outside difference atmosphere. Typically, fluids flow in tubes in two distinct ways, LAMINAR FLOW TURBULENT FLOW ‘There is a great deal of mixing in ( turbulent / laminar ) turbulent ‘The type of flow in which the fluid flows in smooth stream- lines is —tlow. laminar ‘As the fluid flows, the molecules of the fluid rub against ‘one another. The friction of the molecules against each other causes ‘a resistance to flow, which tends to ( speed up / slow down } flow. slow down29, 30. 31 19 shows fluid flowing near the wall of a tube. STATIC FILM MAINSTREAM ‘TUBE WALL ‘The fluid that is flowing closest to the tube wall (is /is not ) turbulent ‘The friction of the fluid closest to the tube wall causes this fluid to flow ( quickly / slowly } This slow-tlowing fluid acts as a static film covering the tube wall Heat travels through the tube wall by conduction, and, in order for the heat to reach the main stream, it must pass through the static film by aso, Ina turbulent stream, the fluid molecules mix to a great ‘extent. ‘As the mixing process continues, (many / few fluid mole= cules come in contact with the static film. aadtfnen these fluid molecules come in contact with the 33, a4 36, 36, 37. 38, static film, they (absorb / give off] heat. The molecules which have absorbed heat from the static fil some of the heat to other molecules in the mainstream. Heat is transferred to the molecules that come in contact with the static film by ( conduction / convection } These molecules carry the heat to another part of the mainstream and transfer some of the heat to other mole- cules. This is heat transfer by In turbulent flow, the transfer of heat from the static film ‘tothe mainstream is by fond et op Fluid farther from the tube wall flows ( faster / slower } The fluid that is flowing fastest is ( in the center / at the edges } of the mainstream. is not slowly conduction many absorb transfer conduction convection ‘conduction; convection faster Inthe conter99. Fluid in laminar flow acts much as if it consisted of many, ‘thin-walled tubes ofthe fluid, one inside the other, Tuse MAINSTREAM In order for the mainstream to absorb heat, the heat must be from layer to layer. conducted, or transferred 40, A fluid can be expected to absorb heat at @ faster rate in (Cturoutent / laminar flow. turbulent 41. In comparison to metals, fluids are poor conductors. In comparison to the tube wall, the time it takes for heat to transfer through the static film is ( greater / loss) less } 42, The thicker the static film, the ( greater / loss ) the heat less transfer time. 49, Heat transfer time can be decreased by ( increasing / decreasing ] the thickness of the static film. decreasing 44, The thickness of the static film depends on the amount of turbulence, When turbulence is slight, the static film is thick ‘As turbulence becomes greater, the static film becomes hse thinner, oF less 45, Heattransfertime through the static film can be decreased by increasing the of the flu. turbulence48. Different fluids are flowing on both sides of a tube. OUTSIDE FLUID STATIC FILM TUBE WALL. STATIC FILM INSIDE FLUID STATIC FILM TUBE WALL. STATIC FILM OUTSIDE FLUID ‘The friction of the outside fluid on the tube wall causes the fluid closest to the wall to flow ( quickly / slowly). slowly 47, Thé fluid closest to the tube wall becomes a : static file 48. Assume that the fluid outside the tube is hotter than the fluid inside the tube. Heat flows from (inside to outside / outside to inside ) of outside toinside the tube, 49. In order for the heat to reach the tube wall, it must pass from the mainstream through the static film 0. The greater the turbulence outside the tube, the (thicker / thinner } the static film, thinner 51. The greater the turbulence outside the tube, the ( more / more fewer ) molecules come in contact with the static film. 52. The factors affecting heat flow inside and outside tubes are ( similar / different }. similar53, This drawing illustrates flow inside and outside a tube. i i { ; H FLUID INSIDE TUBE ued wa, INSIDE FLUID FILM INSIDE FOULING MATERIAL FLUID OUTSIDE TUBE OUTSIDE FOULING MATERIAL OUTSIDE FLUID FILM. 71, the temperature inside the tube, is ( higher than lower than } Ts, the temperature outside the tube. 4, The line segment between Ts and Ts,represents the temp- frature drop across the inside 55. Ts to Ts's the temperature drop across the inside scale or fouling material. Compared to the drop from Ts to Ts, the drop from Tsto Ts is (steeper /less steep } 56. T.to Tsrepresents the temperature drop through the tube wall and Tso Te represents the drop through the outside fouling material The temperature drop through the tube wall is close to higher than fluid film steeper zero57. The temperature drop is greater ( through the tube wall / through the inside and outside static films ) 58, The shape of the outside temperature curve is (similar to / different from } the shape of the inside temperature curve Parallel Flow ~Countertlow ‘59. Heat flows from one fluid to another if there isa—___ in temperature between the two fluids, 60. Assume that fluid is flowing along both the inside and the ‘outside ofa tube and that both streams of fluid are flowing in the same direction and that the fluid inside is hotter than the fluid outside Heat is transterrod from the _______ fluid to the ‘ld. 61, The temperature of the hotter fluid (increases / decreases } 62. As heat is transferred to the colder fluid, its temperature 63. Allthe fluid represented here is flowing in the same direc- tion. Ss 3} ae ees The temperature of the inside (hotter) fluid is greatest at point (A/B/C), 64. The temperature of the inside flu (AB/C). is lowest at point 65. The temperature of the outside (colder) fluid Is lowest at point (A/B/C), 10 through the inside and static films similar to difference Inside outside decreases increases66. The temperature of the outside fluid is highest at point (A/B/C), c 67. This graph shows the temperature of the two fluids in relation to the length of the tube. PARALLEL FLOW ieee ‘TEMPERATURE ! 1 1 1 I I I POINT A POINT s POINTC The difference in temperature is greatest at point ( A / A B/C). 68. The heat transfer rate ( depends / does not depend } on depends the temperature difference 69. The heat transfer rate is greatest at point( A / B/C). A 70. At point C, there (is / is no } temperature difference. sno 71. At point C, heat (is / is not) transferred. isnot 72. In parallel flow, when both fluids flow in the same direc tion, the hot fluid { can / cannot } be cooled below the cannot highest temperature of the cooler fluid. 78. The fluids are flowing countercurrently. In this kind of flow the fluids are flowing in ( the same direction / opposite directions } ‘opposite directions "74. 75. 76. 77 78, 79, 20. ‘Suppose that two fluids are in countertiow inside and out- side a tube. and the hotter fluid is inside, The temperature of the hotter inside fluld is greatest at (A/B/C) ‘The temperature of the inside fluid decreases in the direc- tion (Ato C/Ct0 A}, The outside colder fluid is coolest at (A / B/C). The outside fluid is hottest at (A/B/C) This graph shows the temperature in relation to the lenath of the tube. TEMPERATURE if OUTSIDE FLUID i 1 1 1 1 1 ' I I i Point a Pointe Ponte In counterflow, the temperature difference along the tube is ( more constant / less constant } than the temperature difference in parallel flow. The heat transfer rate in counterflow varies ( consider- ably / little ) over the length of the tube. Notice the area on the graph that is represented with a double arrow. Counterflow ( permits / prevents } cooling a fluid to a temperature lower than the highest temperature of the cooling fluid 2 Aloe more constant little permitsSection 2: Heat Exchanger Equipment Introduction 81. A.simple heat exchanger is a set of steel tubes enclosed in tank HoT OIL, The tank represents the shell of the exchanger and, in this case, is filled with 182. Heat is transferred from the hot oil flowing through the tubes to the cool water around the tubes. The conductor of the heat is the — wall 83. The shell-side of an exchanger is the area inside the shell and outside the tubes. ‘The tube-side of an exchanger isthe area the tubes, ‘84. Inthe example shown, the shell-side fluid is land the tube-side fluid is 13 water tube inside water oil85. This drawing shows the construction of a typical shell and tube exchanger. ‘TUBESHEET The tubes are anchored between two ‘86, The combination of tubes and tubesheets is called the tube — 187. This drawing shows the fluid flow path through a shell and tube exchanger ‘TUBESIDE INLET SHELL SIDE INLET HoT oI, ‘COOL WATER: ‘TUBESIDE OUTLET ‘COOLED OIL SHELL SIDE OUTLET WARM WATER Hot oil flows into the tube-side inlet, through the tubes, and out through the ___" outlet 88. Cool water fiows into the shell-side inlet, around the and out through the shell-side outlet £89. In this example, heat is transferred from the ( tube-side / shellside | fluid to the fluid tubesheets bundle tube-side tubes tube-side; shell-side‘TUBE BUNDLE 90. The greater the surface area of a conductor, the ( more / less } quickly heat is conducted, more 91. A bundle of small tubes has ( more / less ) surface area more than a single large tube. 92, Shell and tube exchangers use a bundle of small tubes, rather than a single large tube. This ( increases / decreases ) the area for heat transfer. increases 93. Exchanger tubes can be either plain or finned, As these drawings show, fins are either inside or the tubes. outside 94. Fins add to / subtract from ) the tube surface area. add to 95. Thus, hey ____the rate of heat transfer. increase 96. tacorrosive fluid passes through either side of an exchanger, something usually must be done to prevent corrasion 97. Sometimes the tubes can be made of a metal which is not (aslly ace corroded Reter to Exhibit 1 for frames 98-100. 98. The outside diameter (0,.) ranges from 1/4-inch to 242 inches. 99. Inpractice, the mostcommontube O.0/sarethe 1/2-inch, the $/4-inch, and the one-inch, {As the chart shows, tubes with O.D’s at the extremes of the range, either high or low. are usually produced in ( greater / fewer } varieties of gauges than the more com- fewer mon sizes,100. So, tubing with 2 2-1/2 inch O.D. is usually produced in onlyone 101. Exchangers are usually produced in standard lengths of 8,10, 12, 16, and 20 feet. Sixteen and 20 feet are the most ‘common lengths. ‘The particular application usually determines the —_ of an exchanger. 102. That is, exchanger design is determined by cost and the particular operating 103. As the length of an exchanger increases, its cost genor- ally (increases / decreases }. 4104. One of the basic considerations in exchanger design is to ‘meet operating requirements while minimizing ——__ TUBESHEETS 105. The tube bundle is made by fastening the tube ends into ‘openings in the tubesheet ‘TOBE SHEET Because the tubes cannot move in the tubesheets, the tubesheets and tubes forma solid / flexible } unt, 16 gauge, or thickness length conditions, or applications Increases cost solid108, In some exchangers, the tube and tubesheets are fixed to the shell Therefore, they ( are free to move / are prevented from are prevented moving }, from moving 107. Heat causes metal to expand / contract } expand 108. Whon the tubes expand because of heat, stress is placed fon the tubes and tubesheet. ‘Atube can come loose, allowing fluid to leak between the tube wall and the opening inthe es tubesheet 109. This results in the contamination of one fluid by another. ‘To guard against this, a double tubesheet can be used in cases where 2 absolutely cannot be leak tolerated110. Here is a design which can help reduce the possibilty of leaks at the tubesheet, DousLe TOsESHEET This design provides for a_______ between the space tubesheets, 111. Ifaleak occurs, fluid passes into this space. Since the space between the tubesheets is open. fluid is allowed to ( drain from / collect in } the exchanger. drain from ‘TUBE JOINTS 112. The tube joint is the connection between the tube and the tubesheet. The better the fit at the tube joint, the less the possibility at there is leakage.119. Tube joints are usually either rolled press fit or welded, WELDED ROLLED PRESS FIT (EXAGGERATED) Some metals cannot be welded, so tubes of these metals are rolled 114, Rolled joints usually make a very good seal, and they can be used in reasonably high pressure service. up to about 2,000 psi However, in special cases or severe service, welded tube joints are usually used. 118. An exchanger Is likely to be more expensive if the tube Joints are ( rolled / welded } welded TUBESHEET LAYOUT 118. Exchanger tubes can be installed in a variety of patterns, TRIANGULAR INLINE TRIANGULAR IN-LINE SQUARE DIAMOND SQUARE When the tubes are arranged in parallel rows, vertically. and horizontally, the pitch is called ——-_____ indine piteh.118, 119. 120, 121 122, 123, 126, 125. In-line square pitch offers the ( most / least) resistance to shell-side flow through an exchanger. The greater the 1 ing pressure drop. istance to flow, the greater the result For this reason, in-line square pitch is particularly efficient, when conditions require a ( high / low } pressure drop. Staggering the tubes, as in the three other main types of pitch, allows ( more / fewer }tubes in a given area than the ‘even spacing in square pitch does, A disadvantage of square pitch is the relatively number of tubes in a given area Compare the number of tubes in a given area in square pitch and triangular pitch, SQUARE PITCH | TRIANGULAR PITCH Number of Passes | Number of Passes aS |ostaee aia | extn rca la 241 | 236 | 224 | 269) 260) 250 300 | 280 | 280] 337) 390) 14 360 | 350 936] 421) 404) 380 424 | 412 | 402 | 499] 476 | 460 402 | 498 | 480} s7o| se2| saz 580 | 566 | 566 | 668) 048 | 636 732 834 942 605 | 648 | 644 | 766 | 744 756 | 758 | 790 | 870] 850 353 | 848 | 832 | 86 | 978 973 | 950 | 998 | 1108 | 1100 | 1060 }1085 | 1064 | 1052 | 1236 | 1228 | 1200 1201 | 1176 | 1162 | 1367 | 1350 | 1322 Ina 42-inch, double-pass exchanger, there are tubes in a square pitch arrangement and __ tubes in a triangular piteh arrangement. ‘The more tubes there are ina given area, the the heat transfer rate, ‘Since the square pitch arrangement results in the lowest umber of tubes in a given area, it also results in the heat transfer rate ‘When the pitch is triangular, the pressure drop is (higher / lower } than when the pitch is square. But, the heat transfer rate is greater when pitch is. 20 least more low, or small higher, or greater lowest higher triangular128. For agiven set of operating conditions the choice of pitch arrangements depends upon what pressure dropis needed in relation to the ‘transfer rate desired. BAFFLES AND TYPES OF BAFFLES 127, 128. 129, 190. ‘The longer the tubes in an exchanger are, the ( heavier / lighter } they are ‘The heavier they are, the the chance that they will sag, Baffles support the weight of the tubes, ‘Since they support the weight, baffles help to the sires on the tubing and tubesheet In both laminar and turbulent flow, a layer of fluid sur- rounds each tube, acting as an insulator. This layer of fluid acts to ( increase / decrease } the rate ‘of heat transfer. a heat heavier ‘greater decrease, or relieve decreaseit more 11. The thicker the insulating layer, the decreases heat transfer. 192. The insulating layer is likely to be thicker when flow is (laminar / turbulent j laminar 193. In addition to supporting the tubes, baffles break up flow, decreasing the layer of insulating laminar fluid. ‘Segmental Battles 194. segmental baffie isa circle from which either a vertical Cr horizontal portion has been cut In this case, the batties are ( vertically cut / horizontally vertically cut cut ) segmental battles 195. Segmental battles are positioned so that the cut-out areas (allface in the same cirection / face in alternate directions) face in alternate directions 196. Alternating the baffles causes flow to the cross, or pass tubes a number of times. 187. It also provides better _____ for the tubes. support188. In addition to the portion cut from the side or top of a seg- ‘mental baffle, a portion is often removed from the bottom, HORIZONTAL VERTICAL Removing this portion ( allows / prevents } some contin- allows ‘uous fluid flow along the bottom ofthe exchanger 199, Whether the batfie is cut vertically or horizontally depends on the type of fluid and on the operation HORIZONTAL, VERTICAL The baffle most likely to catch suspended materials is the (vertical / horizontal} battle. horizontal 23.140. But, suppose horizontal baffles were used in a condenser, GAS INLET, CONDENSED FLUID OUTLET Condensed fluid builds up behind baifies A and C, thus = — flow. restricting 4141. Drainage from the condenser is prevented and the effi- ciency of the exchanger i decreased Disc and Doughnut Battles 142, The pattern of flow through disc and doughnut baffles is relatively uniform But, if the fluids are not clean, sediment builds up behind the { dise / doughnut } doughnut,143, Since the cutout area of the baffle is in the center, the low of condensed fluidsalona the bottom of the exchanger, can also be 144, For these reasons, disc and doughnut baffles are used (‘more / less ) often than segmental baffles. Impingement Battles 145. At high inletluid velocities, the fluid can seriously erode the tubes as it strikes them. If the inlet fluid contains suspended solid particles, the problem is (more / less ) severe 146. Impingement baffles are sometimes placed at inlet flow areasto the shell-side. NOPLATE BAFFLE ee a £& i PLATE BAFFLE VERTICAL CUTS PLATE BAFFLE ee HORIZONTAL CUTS {As this comparative illustration shows, the impingement baffle helps to ( spread out / contain } fluid flow. 147, An impingement battle directs the flow ( toward the sides of the exchanger / toward the tubes } 148, The baffle effectively reduces the tubes. of the 25 restricted less more ‘spread out toward the sides of the ‘exchanger erosion149, Besides reducing erosion, spreading the fluid insures that the fluid contacts all the tubes. ‘And increasing fluid-tube contact _____ the increases heat transfer rate, Longitudinal Battles 180. Longitudinal baffles are sometimes used to splits flow into two or more passes. ‘Asthe drawing shows, the longitudinal baffle (is somewhat shorter than / extends the full length of } the exchanger. is somewhat shorter than 161. This allows for the return, or double pass, through the ‘exchanger, Three longitudinal baffles would provide for ___ four passes through the exchanger. 26152. This drawing illustrates the batfle position for divided flow. Inthiscase, fluid flow on the two sides ofthe tubes is ( con- secutive / simultaneous ) EFFECTIVE HEAT TRANSFER SURFACE 183, 154, 185, 158, The heat transfer surface depends on the number of tubes, onthelengthofthetubes, andontheoutsidediameterof the tubes. ‘Asany ofthese increase, the effective heat transfer surface dao ther es or ‘The entire length ofa tube is not the effective length of the tube, as far as heat transfer goes. Since the tube extends through the tubesheet at each end ofthe exchanger, theeffective lenatis than the actual length, For 15-foot tubes extending three inches through a tube- sheet al each end, the effective lenativis about foot The formula for calculating the effective tube surface ‘exchangeris: Effective surface = (square foot external surface per foot length) x net effective tube length x inumber of tubes) an If the square foot of external surface per length is 2618 and the net effective tube length is 15.5 feet and the num= ber of tubes is 682, then the effective tube surface is ar simultaneous increases shorter.orless 14-1/2 (15 feetminus sixinches) 2618x15.5x682SHELL AND TUBE FLOW ARRANGEMENTS Reterto Exhibit2fortrames 157-164. ‘ShollSide Flow Arrangements 187. 168, 159. 160. 161 162, 163. 164. Shelt-side flow arrangements are generally one of the six illustrated in Exhibit 2 Ina one-pass shell, the shell-side fluid enters one end of the exchanger, flows through the exchanger, and exits ‘through ( the same / the opposite ) end of the exchanger. ‘A couble pass requires that fluid enters and exits through (the same end / different ends ) of the exchanger. ‘As the exhibit shows, a split flow arrangement divides incoming shell fluid into __ separate streams. ‘A double split flow divides shell fluid into, separate streams. In the divided flow arrangement shown, shell fluid enters atthe of the exchanger, rather than at the end, ‘The kettle-type reboiler has ( split / divided } flow and a dome outlet for vapors, ‘The choice of shell arrangement depends on the amount cof cooling or heating required, on the pressure drop that is needed, andon the type of service. For instance, the shell arrangement that provides space for vapors to accumulate is the eee ‘The effective “time” that the shell-side fluid is in contact «with the tubes inereases as the number of passes. 28 the opposite the same end two four center, or middle divided kettlo-type reboiler Increases‘Tube-Side Arrangements 165, The drawing illustrates a single-pass tube arrangement. ‘TUBESIDE INLET. SHELL SIDE INLET HOT OIL, ‘COOL WATER ‘TUBESIDE OUTLET (COOLED OIL SHELL SIDE OUTLET WARM WATER. ‘Tube-side fluid enters one end of the exchanger, flows: through all the tubes in the same ge sand direction leaves at the opposite end of the exchanger. 166, A tube-side baffle can be built into the head end of the ‘exchanger to direct flow through the tubes. (CHANNEL HEAD CHANNEL BAFFLE In a two-pass arrangement, fluid flows through half the tubes in one direction and through the other half of the tubesinthe -.____ direction opposite 167. This requires ________ channel head battle and one no head battle, 168, The channel head baffle in a two-pass tube arrangement is positioned { vertically / horizontally horizontally 20169. Compare the two-pass arrangement with the four-pass arrangement. CHANNEL BAFFLES HEAD BAFFLE ‘Afour-pass arrangement requires _chan- nel head batfle(s}and floating head baf- fle(s) 170, Increasing the number of passes requires the number of battles ‘TYPES OF SHELL AND TUBE EXCHANGERS Fixed Tubesheet Exchangers 171. In the fixed tubesheet type exchanger, the tubesheet is welded to the shell ‘Ube sueer The tube bundle ( can be removed from the shell /is per- ‘manently installed | Increasing is permanently installed ‘Now turn the | ‘urn the book over172, Expansion and contraction because of temperature ‘changes place stress on the tube bundle. In this type of exchanger, the tube bundle ( can expand to compensate for the stress / is prevented from expand- is prevented from ing). expanding 173, Fixed tubesheet exchangers are used when the tempera- ture range is (limited / wide } limited 174, The drawing shows an expansion joint built into the shell of a fixed tubesheet exchanger. EXPANSION JOINT ‘As the tubes become hotter, they { expand / contract ) expand 175. The builtin jointallows the shell to_____also, expand 176. Asthe tubes and shell cool, the expansion joint and tubes eta tents contract 177. Stress on the welding and on the tubes and shell is lessened. or decreased 178, Because ofthe difficulties of inspecting and cleaning fixed tubesheet exchangers, they are generally used where shell-side fouling is (limited / extensive ). limited 179. Because the tube bundle cannot be removed from the shell, the shell side of a fixed tubeshoet exchanger must be cleaned { mechanically / chemically ). ‘chemically Refer to Exhibit 3 for frames 180-189, U-Tube or U-Bend Exchangers 180. Exhibit 8 shows a U-tube type exchanger. ‘As the drawing shows, a U-tube exchanger has ( only Pee ‘one / two } tubesheot(s. cf 181. Abaffied channels bolted between the tubesheet and the Channel Ce cover ar182, 183, 184, 185, 186, 187 108, 129, ‘The tubesheet and tube bundle form a unit By unbolting the channel from the shell the tubesheet and tube bundle can be removed from the shell 90 the (inside / outside J ofthe tubes can be cleaned. However, the bend in the tubes inhibits cleaning and Inspecting the —____of the tubes. Since the tube bundle in a U-tube exchanger is fastened to only one tubesheet, the tubes are ( free to expand / prevented from expanding } Uztube exchangers can be used where the temperature sifference between shell-side and tube-side fluids is quite Exhibit @ also shows the flow patterns in a U-tube exchanger ‘The battle dividing the channel directs incoming tube-side fluid through (all / only the upper half ) of the tube open- ings. ‘Tube'side fluid flows through the tubes, around the bend, and through the chamber. Tube-side flow. in this case, is one-pass / two-pass } flow. ‘Shell-side flow in this exchanger is ( one-pass / two-pass ) flow. Floating Head Exchangers PULLTHROUGH TYPE 190, In this exchanger, the tubesheet on the right is bolted ‘between the channel and shell in a fixed position. | soar eo But, the tubesheet on the left, together with a cover, floats inside the shell, ( free to move / unable to move } hori- zontal, 32 outside inside free to expand ‘reat, high, or large only the upper halt lower two-pass one-pass tree to move191. Because of the weight of the tube bundle, there (is /is no) sno vertical movement, 192. But, since the tube bundle and floating head can move horizontally. the tubes are free to __ and ‘expand ioe ete iG 2b contract 193. Afterunbolting the channel flange and the stationary tube- ‘sheet, the tube bundle and the floating head can be with draven as a unit ‘TUBE BUNDLE FLOATING HEAD This permits cleaning and inspecting the of the tubes. aa outside 194. In this illustration, the channel cover, the shell cover, and the floating head cover have been removed. SHELL COVER FLOATING HEAD COVER This provides access to both tubesheets and to the of the tubes. insides 33195. 196, 197. 198. 199. 200. By removing the floating head cover and the channel cover, itis possible to inspect and clean the of the tubes, in a pullthrough type floating-head exchanger ( all / some } parts of the exchanger can be inspected and cleaned. This drawing illustrates a disadvantage of the pull-through exchanger. CLEARANCE ‘The clearance between the shell and the —__ is large. ‘This clearance is provided to accommodate the outside diameter of the floating tubesheet. Since no tubes can occupy this space, the space is In addition, fluid is likely to move through the space rather than past the tube For these reasons, the clearance space between the shell and tube bundie______“‘the efficiency or effect- iveness of the pull-through exchanger. 34 inside all tub wasted bundles reducesSPLIT BACKING RING TYPE 201. 202. ‘A second flosting head exchanger is the split backing- ring type. FLOATING TUBESHEET CHANNEL SHELL \ sour runt "Notice that the diameter of the shell cover is —___ than the diameter of the rest of the shell holding the tubes. ‘The tubes and tubesheet and floating head cover { can be pulled / cannot be pulled } through the channel as a unit. Reter to Exhibit 4 for frames 208-215. 203, 204. 205. 208, 207. Compare the split backing-ring exchanger and the pull- through exchanger. ‘An advantage of the pullthrough exchanger is that the bundle and head can be pulled through the channel as unit In order to pull the tube bundle of the split ring type, the floating head cover, shell cover, and the split ring must be aire However, clearance between the tube bundle and shell is smallerin the ( splitbacking-ing / pullthrough ) exchanger. Ifthe same amount of space is available, more tubes can bbe used in the (split backing-ring / pullhrough } exchanger. ‘Therefore. the split backing-ring exchanger is — efficient than pull-through exchangers. 368 greater cannot be pulled one removed split backing-ring split backing-ring208. But, the ( split bcking-ing / pull-through } exchanger has more parts. 209, Thus, itis _____ expensive to build. 210. The split backing-ring exchanger is also ( easier / harder ) to disassemble, 211. First, the shell cover is unbolted from the 212. Then, the floating head cover and split backing-ring ar Lnbolted from the floating 213. Then, the channel Lnbolted from the other end of the 214. And finally, the tube bundle is pulled from the end 218. Since disassembly is more time-consuming, itis also more SIZE NUMBERING AND TYPE DESIGNATION 216. Exchanger size, as specified by the Tubular Exchanger Manufacturer's Association (T-E.M.A.), depends on the diameter of the shell and length of the tubes in inches. Since shell diameter is specified first, a size 29-192 ‘exchanger has a diameter of __inches and tubes inches long 217. When the shell diameter is between two numbers, such as rounded off to the nearest whole num- ‘An exchanger with a 33 1/4 inch diameter and 188 inch long tubes would be designated size Reter to Exhibit2 again for rames 216-228. 218. Asthe exhibit shows, type designation includes three vari- ables: the type of stationary —_ the type, and the type of head 219. Designations are specitied by letters ofthe alphabet. ‘The four designations of stationary head types are indi- ‘cated by the letters —__. and 208 special tah pressure saonary head closures are in cated byte feter 36 split backing-ring harder shell tubesheet shel channel ‘costly, orexpensive 23 192 head; shell rear A: B:0;D201 222. 223, 224, 228, 228, 207. 228, Shell types are indicated by the letters —__,. _, asi and a ‘Any exchanger including the letter K in its designation is a kettle-tyoe: Rear head types ar specified with the letters and ‘An example of a complete exchanger designation is size 17 This exchanger has a type AES, inch long tubes. -inch diameter and ‘According to the exhibit, this exchanger has @ { removable channel and cover / integral cover). Ithas a ( one-pass / two-pass / split flow )shell ‘And. it has a ( fixed tubesheet / U-tube bundle / floating head with backing device ) ‘Suppose an exchanger were described as a fixed-tube- sheet exchanger having stationary and rear heads integral with tute sheets, single-pass shell, 17-inch inside dia- meter and tubes 16 feet long, Its designation would be size 37 st Type e GiHiusk reboiler iE M;NP)S:T;U 17,192 removable ‘channel and cover one-pass floating head with backing device 17-102 CENSection xchanger Operation and Maintenance STARTUP AND SHUTDOWN, 229, 230, 231 232. 233, 234. 238, 236. 237. 238, 239, 240, 241 ‘A mixture of hydrocarbons and air is dangerous because of the possibility of ‘Therefore, before adding a liquid or a gaseous hydrocar- bon to an exchanger. inert gas or steam is used to purge — from the exchanger. ‘The shell and tube bundle of an exchanger may be made of different metals which react differently to temperature changes. Insuch a case, the shell and tube bundle expand at (dit ferent rates / the same rate ) when heated to a particular temperature, Ifthe shell and tube bundle do expand at different rates, the metal and structure are subjected to ‘Asudden temperature change causes {rapid / moderate ) ‘expansion or contraction. ‘The tube bundle and shell experience more. than usual ‘As a result, tubes can be loosened from the tubesheets, Or tubes can be — For these reasons, cold fluid should never be suddenly Introduced into a hot exchanger. Similarly, a hot fluid should never be introduced suddenly intoa exchanger, During startup and shutdown, any temperature changes should be made ( slowly / rapidly ). During startup, the cooling fluid is introduced fist. ‘Then, the Not fluid is gradually added, and the exchanger Is brought to — —_— temperature. During shutdown, the flow of hot fluid is stopped fist. With no input of hot fluid, the exchanger gradually —_ ‘Then the flow of ____ fluid is stopped. ‘The exchanger should not be valved closed while it is full of fluid ' Just like a solid, aliquid _ when it is heated. 38 explosion, or ignition alr, oF liquids different rates stress. rapid stress broken, or ruptured cold slowly ‘operating, or correct cools cold ‘expands242, 249, 244, 248. 246. 247, 248. 249. 250. 251 252, 253. 254, This is called thermal expansion, When liquid expands, its volume the expanding liquid is enclosed, it exerts fon its container ‘Therefore, a filed exchanger which is valved closed can bbe damaged by tule For this reason, the exchanger must be before being valved closed. It the outside temperature is low. water left in the exchanger tubes can. aoe, When water freezes, it expands Expansion puts excess — con the inside of the tubes, Excess pressure can cause For this reason, the operator must consider the tempera ture surrounding the exchanger. It is usually best to completely —_ ‘exchanger. — the Water in the tubes can also freeze as a result of the rapid depressurizing of light hydrocarbons in the shell side of the exchanger. Malighthydrocarbonis suddenly depressurized, it (evapo- rates / condenses ). ‘As a liquid evaporates, it cools the surface from which it evaporates. ‘Theretore, the evaporating hydrocarbon cools the inside walls of the shell and the ________ of the tubes. ‘Sudden cooling causes water inthe tubes to Just as in startup operations, care must be taken during shutdown to avoid potentially explosive mixtures of ‘and hydrocarbons. Therefore, itis necessary to__ some exchangers Of air with steam or inert gas after shutdown, OPERATING PRESSURE AND TEMPERATURE 255. Every exchanger is designed to operate at a pressure and temperature listed on a plata attached to the exchanger. ‘When the exchanger is operated at a pressure higher than the rated pressure, chances of ube or shel failure {increase / decrease | 39 increases force, or pressure expanding drained, or emptied freeze pressure damage rain evaporates outside freeze purge, or clear Increase256. 2s7, 258, 250. 260. 261 262. 263. 264, 265. 266. 267, 268, ‘Suppose a high operating pressure resulted in rupture of a tube or ina tube being pulled from the tubesheet. This ( would / would not } result in fluid contamination. Ina typical recirculating cooling water system, corrosion Inhibitors and acid are added to prevent scale from forming The scale is still (dissolved in the fluids / soli ) High temperature causes this scale to precipitate out as ——— in the exchanger. Such precipitates collectin the tubes and______flow. In some fluids, precipitation occurs if the temperature is to0 low. ‘Temperature must be held within the selected so that fouling is prevented, Inwater dropout processes where heat is used to separate ‘water from hydrocarbons, too (low / high } a temperature decreases efficiency. Ifthe outlet temperature is too low, decreasing the rate of water flow would ( increase / decrease } the rate at which heat leaves the exchanger. So, temperature in the exchanger would ‘One way of controlling temperature within the exchanger, then, is by controlling the ____of water flow. The velocity must not be allowed to drop too low and the cooling water tomperature must not be allowed to go too high, Otherwise, solids may precipitate and ____ the ‘exchanger. In some cases, the outlet temperature can be raised by bypassing some of the product stream around the exchanger and joining itto the product flow which has passed through the exchanger. {In this method, (part of the product / all of the product } is cooled ‘The exchanger is part of a system which consists of other pieces of equipment. ‘Since they are connected, whatever happens in the way ‘of physical change in one piece of equipment ( affects / hasnocffecton |the operation of each piece of equipment within the system ‘The operator should consider what changes will o¢cur in other parts of tne ___iftachange is made in the operation of an individual exchanger. 40 would dissolved in the fluids solids restrict range low decrease rate foul, or plug part of the product, affects system269. 270. Itis a good idea to observe temperatures, pressures, and flow before and after changes are made. ‘This vl give the operator an accurate idea of how cond! tions have actually changed, and he will be able to pir point — in operation. For the same reason, a record should be kept of how and where changes are made. In the event that changes produce unsatistactory results, the ‘can be returned to its original operat ing condition EXCHANGER FOULING. an 272, 278. 21a, 276. 276. arr. 278. 279. 280. Fouling is a general term which describes the buildup of various kinds of deposits on the parts of an exchanger. Since fouling particies adhere to the tube wall, fouling effectively the thickness of the tube wall ‘When the tube walls fouled, ittakes heat to pass through the wall In other words, the time of heat transfer { increases / decreases ). In addition, the flow of fluids through the exchanger is Fouling in an exchanger causes a general of efficiency. Trouble in an exchanger is almost always indicated by ‘changes in temperatures and pressures, Itfouling restricts the passage of fluid, the drop in pressure ‘across he exchanger will increase / decrease ) In adgition, the flow rate may {increase / decrease } The temperature will indicate that heat is transferred ——ettectivery One type of fouling Is sedimentation. ‘As the name indicates, sedimentation involves ( a chem- ical reaction / deposits of dirt and clay and dust ). Corrosion products are another source of fouling deposits. Corrosion products are formed when ( exchanger mater- lals interact with the fluids / two fluids come in contact ) a difficulties, or problems system increases longer restricted, or decreased loss, or decreast increase decrease deposits of dirtand clay ‘and dust ‘exchanger materials interact withthe fluids281 282, 283. 284. 285. 286. 287 288. Organic material growth includes algae growing in cooling water, ‘Algae on the inside of tubes forms ( a conducting / an insulating } layer, ‘Other types of fouling include coking, salt deposits, and ‘chemical reaction, Regardless of the type of fouling, deposits reduce the rate of _Wscasseee ‘The kind and degree of fouling are influenced by the materials used in an exchanger. For instance, surface roughness ( provides cavities for / discourages ) the buildup of deposits ‘Some materials corrode faster than others, providing cor- rosion products which decrease heat transfer. ‘The higher the corrosion rate, the sooner —__ es ‘occurs. ‘The velocity of flow affects fouling rates. ‘The lower the rate of flow, the ___the seai- ‘ment that is allowed to drop out of the stream. Up to @ point, increasing the velocity the. fouling rate Fouling in an exchanger can be handled in a number of ways. Antfoulants ( prevent the formation of / break-up } deposits, Inhibitors prevent chemical reactions which might cause to build up. MAINTENANCE 289. 200. 201 Dispersants prevent the coagulation of insoluble materi- is that are suspended in the fluids. ‘The method used for removing the deposits depends on what they are, ‘The severity of the deposits also determines the method of é If a fouling problem has been neglected for some time, ‘mechanical cleaning, such as cutting or scraping, may be necessary, ‘The exchanger must be disassembled to use cleaning techniques. 4 an insulating heat transfer provides cavities for fouling decreases prevent the formation of deposits kind mechanical292. However, many deposits can be removed without shutting down the exchanger Cleaning while the exchanger is operating is called ( on- line / offline } maintenance, on-line 293, Ina typical method used for on-line maintenance, chem- icals are added to the flowing through fluids, or fquids the shellside or tube-side. 294. The drawing shows how sodium chloride (salt) deposits ‘can be washed from the outside of tubes, while the exchanger is in use. iwiect WATER HYDROCARBON FROM TOWER OVERHEAD, COOLING WATER tL —_* vonocarson: WATER; AND SALT HYDROCARBON Be PRODUCT eee WATER AND SALT Water is injected into the ( hydrocarbon / cooling water } hydrocarbon inlet. 295. As the mixture of water and hydrocarbon flows over the tubes, the water the salt. dissolves 296. In the acoumulator, the product and the salt water solu separated tion are a 297. Insome cases, itisadvantageous to shut-down the exchanger for either chemical or cleaning mechanical 298. Itis not necessary to dismantle the exchanger for ( chem- ‘eal / mechanical ) cleaning, ‘chemical 299. A cleaning solution is circulated through the tubes or the -side, shell 43,300, 301 302, 303. 304, 308, 306, 307, For mechanical methods of cleaning, the exchanger is, partially or____" "dismantled. The drawing shows a water jet used for hydroblasting, a commonly used cleaning method Water, under high 's sprayed on the ‘outside or inside of the tubes The force of the water loosens the and washes them away. Steam jotsare also commonly used for heavy hydrocarbon deposits. ‘The heat generated by the steam softens the deposits and the ‘of the steam jet washes them away, For any kind of hydroblasting, the exchanger must be at least partially dismantled. The end plates, or bonnet covers, must be removed to expose the tube tei For the most difficult deposits which resist chemicals or hhydroblasting, _____ methods are used, The exchanger is fully — Drills and other devices are used to cut and scrape the rom the parts of the exchangers. 44 fully, orcomplotoly Pressure deposits force, or pressure sheets mechanicat dismantled depositsTesting for Leaks 308 209, 310, 311 312, 313, 314, 315, 316. 317. 318. Jn the event that the operator suspects leaks inside the ‘exchanger, preliminary tests can be made without dis- mantling, ‘Such tests can be run on either the tube-side or _- side of the exchanger. If the two fluids in the exchanger have different physical properties (like water and oil) itis usually ( easy / difficult ) to tell them apart. ‘The easiest way to test for leaks is to take a sample from the ( higher / lower } pressure fluid. I the fluids are water and oil, for example, then it is easy to see if there is a leak by just __ at the sample. If the fluids are very similar, a chemical test ( may / may not } be necessary. If visual or chemical tests do not indicate a leak, further testing may be necessary. ‘These further tests are called hydrostatic tests, because they usually involve using ___ under pressure. In the case of tube side test, the shell-side fluid is drained, and a drain point, such as 2 disconnected lower nozzle or bleeder valve, is eft ( open / closed } ‘The tube side fluid is replaced with water under pressure which fills the tube bundle. If there are leaks in the tubes or at the tube ends, the pres- surized water in the tube bundle will be forced through the leak points into the ‘Such fluid will accumulate in the bottom of the shell and eventually run out the —____points where it ‘can be observed by the operator. Because the leak may be small and because fluid must accumulate in the shell before it will run from the drain oint, such a test usually takes ( some time / little time } The same kind of test can be made on the shell-side of the exchanger, In that case, the tube-side of the exchanger is drained of fluid, and a tube-side is lett open. 45 shell lower looking may water open shell drain some time drain point319. The shells filled with water under pressure, Fluid running from the tube-side drain point will indicatea leak in the tube bundle. 820. If preliminary tests indicate a leak, the exchanger is par= tially dismantled to determine the of the. source, or cause leak through further tests. 921. In the case of a fixed tubesheet exchanger, the end plates ‘or bonnet covers are removed. Itis then possible to directly observe the tube sheets and tube —__, ends, 822. The shellis filled with water under pressure. ‘The pressurized fluid enters any leaking tube at the point where the tube leaks 828. This fluid accumulates in the tube and runs out of the tube end, WATER UNDER PRESSURE OBSERVE ENDS FOR LEAKING TUBES By observing the tubesheet, it is possible to tell which Is leaking. tube 46924. Aleaking tube can be plugged at both ends with a tapered poreee plug 825. The drawing shows a tube which has come loose in the tubesheet, Such @ leak cen be easily observed on the face of the tube — sheet 826. Tocorrect this, the tube must be rerolled or welded ‘back into the tubesheat. a7827. The drawing shows one method of testing a partially dis- ‘mantied floating head exchanger. (WATER UNDER PRESSURE FLOATING HEAD OBSERVE LEAKS The shell cover has been removed, and the tube bundle is, filled with under pressure. water 928. It is now possible to observe the leak if itis located in the floating head gasket orn the tube endsat the floating head, If the leak is located in the tube walls farther back in the. ‘exchanger ort the tube ends in the stationary head, fluid will be observed in the a ‘shell 829. However. the operator will not be able to locate the source ‘of such leaks because the tube bundle and stationary head ‘ae not Se visible 890. If the leak is coming from one of these areas, a different test Is necessary. WATER UNDER PRESSURE CHANNEL cover Lover on TEST RING FLOATING HEAD END OBSERVE LEAKS The channel cover is removed and tube side fluid i —Acarnect drained 48881. The shel filled with water under pressure, Fluid will enter the tubes at the points where they accumulate in the tubes, and run out the tube ends. 282. By observing the tubesheet, the operator can tell which is leaking, ‘993. Normal test pressure is usually 1,5 times the designed operating pressure. Pressures during testing should never exceed the rated test 384. The operator must also be aware of danger from thermal ‘f fluids in an exchanger which is under test pressure 935. A fluid expanding in a confined space can the exchanger. HEAT EXCHANGE SYSTEMS Reter to Exhibit § for frames 396-358. 336. The heat exchanger system shown in Exhibit § includes a depropanizer, a furnace, and a ype reboiler. 397, The depropanizer supplies the shell-side fluid, which is liquid 888, From the reboiler, isobutane flows back to the depropan- ier asa 839. The tube-side fluid is_—_ 340. Cooled oil from the reboller flows back to the for reheating 841. Because it relates two independent parts of the system. the central part of this system is the. 342. The purpose of the system is to cause isobutane to Using heat generated by the furnace. 843. This cutaway of the keitle-type reboiler permits an inside view of shell-side and tube-side flow. The tube-side fluid.in this system is. 344. Notice that the tube bundle is U-shaped. This is { single-pass / double-pass } flow. 49 leak tube pressure ‘expansion damage, or rupture kettle isobutane vapor hot oil furnace reboiler vaporize double-pass346. 346. 347. 348, 349. 350. 351 352 353, 354. 366. 3656. Shollside fluid, in this case isobutane, enters at one end, Of the reboiler and exits in liquid form { at the same end / at the opposite end ). This is the typical shell-side ( single-pass / double-pass } arrangement ‘The weir pictured at the right end of the reboller functions. asa sort of dam, By assuring that the tubes are always fully submerged in oil, the weir (increases / decreases ) the efficiency of the reboiler. The greater the contact, the greater the rate of heat ‘The tube-side fluid, ol, provides the heat required to cause the shell-side isobutant to ‘The domed area of the reboiler allows the isobutane vapor and liquid to —_ In this particular system, vapors from the reboller are used to heat liquid in trays in the depropanizer. ‘The amount of vapor produced in the reboiler depends on how much is needed in the ‘Suppose that the amount of vapor in the depropanizer needed to be increased To do this, you would need to | increase / decrease ) the input of heat to the reboiler ‘One way todo this is to{ increase / decrease ) the tempera ture of the tube side oil ‘Since the tube side fluid is pumped through the tubes, Circulation in the reboiler system is ( natural / forced }. ‘Another way to add heat tothe! decrease jhe ate of flow of the: ‘Adding heat to a boiling liquid makes it { hotter / boil faster ). at the opposite end single-pass increases transfer boil, or vaporize separate depropanizer Increase increase forced increase boil faster887. The faster the fluid boils. the —_____ vapor it produces in a given time. 358. By changing the flow rate of oil through the reboiler, it is. possible to control ( the amount of isobutane vapor / the temperature of the isobutane vapor } going back to the tower. ‘Thermosyphon Reboilers Refer to Exhibit 6 for trames 359-371. 359. Tho exhibit shows an exchanger used as a thermosyphon, reboile. ‘A liquid {propane and propylene! from the bottom of the fractionating tower is heated in the reboller ana goes back into the tower asa combination of liquid and 360. A thermosyshon reboiler functions like a kettle reboiler in that both break down a liquid into vapor and liquid ‘components, However, the liquid and vapor are removed in separate streams only from the ( keitle-type reboiler / thermosy- ‘phon reboiler ) 361, Exhibit 6 also represents flow through the thermosyphon reboiler. {Ast shows, the propane and propylene are{ shell side / tube-side 862. The shell-side inlet fluid is 369. In the process of giving up heat to vaporize the propane ‘and propylene, the steam 364, When the shel-sde flue leaves the exchanger. it has con- donsed and is a 5 more the amount of isobutane vapor vapor kettle-ype reboiler tube-side steam condenses liquia865, This drawing represents flow on the outside of one tube land on the inside of another. PRODUCT VAPOR [AND DROPLETS oursioe ‘t Prunes | CONDENSING FRopucT STEAM TO WATER VAPOR BUBBLES st oF Tus INSIDE AAs the steam loses heat, it condenses on the outside of the tubes as ee 366, The water collects and runs out the ___ of the exchanger. 367. Inside the tubes, the heat given up by the steam causes ‘some of the propane-propylene to boil ‘The bolling begins closer tothe ( top / bottom } of the tube bundle. 868. A mixture of vapor and liquid is ( heavier / lighter } than an ‘equal volume of just liquid 82 water bottom bottom lighter369. 370, 3m Since the vapor-liquid mixture is lighter than the liquid tentering the inlet, it moves ( upward / downward ) in the tubes. For this reason, moving products through a thermosyphon reboiler does not require a pump. [Aflow of liquid is produced by the formation of —____ Vaporin the tubes flows rapidly, carrying with it entrained droplets of liquid Since they leave the exchanger In one stream, a dome space (is / is not } necessary, Shell and Tube Water Coolers Retr to Exhibit 7 for frames 372-388. 372, 373, 374, 376. 376. 377, 378. 379. 380. 381 Coolers are used to lower the temperature of a liquid or vapor. Inthis example, the product being cooled is Before the kerosene reaches the coolers. it has been pre- cooled intwo crude —_~ ~ exchangers. ‘The cooling liquid in the coolers is 7 The tube-side fluid is water, in this case, and it passes through the exchanger (once / twice | Kerosene, the shell fluid, makes a (single / double } pass ‘through the shell In the shell-side of the exchanger, there is a series of These baffles continually change the —__ the kerosene flow. ot This maximizes the sene and the tubes, between the kero- Theetficiency ofthis single-pass exchanger is| increased / decreased } by the baffles. In many cases, more than one unit is required to do the heat transfer job. In Exhibit 7, two heat exchangers a crude oi usedto__-_ 53 upward vapor is not kerosene pre-heat water twice single battles direction contact Increased pre-heat382 383. 384, 385, 386, 387, 388. Two more are used 10 ______ kerosene for storage. This drawing shows two ways to connect heat transfer Units into a stream. ‘SERIES CONNECTION (ON THE TUBESIDE PARALLEL CONNECTION (ON THE TUBESIDE The incoming flow is split in ( parallel / series } connec- tion, Ina series connection, ( all / only a part ) of the stream ‘908s through each exchanger. In Exhibit 7, the kerosene | flows first through one cooler, then out and into the next / flow is spit, same flowing into ‘one cooler and some tlowing into the others } Theshell-side kerosene flowsin series / parallel) through the coolers. The tube-side water flows in ( series / parallel ) through ‘the coolers, Notice the connections on the crude prehesters. ‘They are connected in con the tube side andin_________on the shell-side. 54 cool parallel tows first through ane cooler. then out and into the next parallel parallel parallelWaste Heat Boilers eter to Exhibit 8 or frames 389-410. 389. The system shown in the exhibit includes a fractionating tower, a steam drum and a waste heat boiler. Heavy oil, the shel-side fluid is drawn off the bottom of the tower. 390, The lube-sidetuidis water drawn trom the 391. The boiler uses the waste heat from the hot ol, which must bbe cooled before itis stored, to produce —_— se for the plant steam system. 992. The shellside ofthe exchanger or boiler has battles ever six inches. il entering the shell flows ( straight through and out / back and forth across the outside of the tubes}. 393. Asit absorbs heat irom the oil, some of the water stars to boil inthe frst half ofthe tubes. STEAM WATER DROPLETS vaPOR aueeLes By tho time the water gets to the other end, most of the space in the tubes is taken up by —_ 384. At the end of the tube, the steam blows along unvapor- ized water in the form of small 395, The water leaves the boiler asa of steam and droplets of water. 396. When the vapor-liquid mixture of water enters the steam drum, the droplets of water fall to the bottom, The lighter steam remains in the ( top / bottom } halt of the steam drum. 55 fractionating steam ‘drum steam back and forth across the outside ofthe tubes vepor droplets mixture top397. 308, 399. 400. 401 402. 403. 404, The steam drum performs a similar function to the dome ina kettle-type reboiler, Itpermits the steam tobe ___ from the water. In order to maintain a constant amount of water circulat- Ing in the system, treated water {is added at the bottom of the steam drum. Inthe steam drum, the new incoming water mixes with the hot / cool ) water recirculated from the boiler. ‘The steam drum is usually positioned above the boiler. When the steam drum is overhead, boiling induces a flow (upward / downward ). The boller with a steam drum above it creates a natural circulation similar to a reboiler. Water absorbs heat betler than steam does. For maximum heat transfer ina boiler, itis better to have (steam / water }in contact with the tube walls. In the boiler in this example, the tubes are extremely hot. It the water does not flow rapidly through the tubes, itis, vaporized near the ( end / beginning ) of the tube. ‘The steam then passes through the remainder of the tube land absorbs (less / more }heat than the water would, Ifthe water boils too soon, much of the heating surface of ‘the tube is wasted. ‘The hot oil simply retains more of its heat and leaves the boiler ata ( higher / lower ) temperature. 56 separated make-up hot upward thermosyphon water beginning less nebo406, 407. 408, 409, 410, Natural circulation by thermosyphon action usually can- rot push water through the tubes fast enough. To increase the flow rate of the water, there isa inthe line between the steam driver and the boiler intake. ‘The pump helps increase the of this exchanger system. The new makeup water is treated at water treatment facili- ties to remove minerals. ‘Some minerals remain in the water even after treatment. ‘As the water is partly boiled and the steam drawn off, then ‘the mineral concentration in the water tends to increase / decrease ). To prevent the mineral content of the water from increas ing, a continuous _____is provided. ‘The blovidown drains off some of the recycled water to ___ the mineral content Troubleshooting Exchanger Systems Refer to Exhibit 9 for frames 41 1-430. an. 412. 413, 414, 415, ate. 447, In a fractionating tower, crude oll is separated into frac- tions, or parts, Light fractions, such as gasoline and naphtha, are taken from the higher levels, and heavy fractions are taken from the levels. ‘The overhead vapors from the fractionator are fed to a In the condenser, heat is transferred from the vapor 10 the cooling fluid, which in this case ts When vapor cools, it or liquifie. Some of the condensed vapor is drawn off through the product line, and some of it is returned to the top of the fractionator as ‘Suppose that the pressure in the fractionator is too high. The problem may be caused by too high a__rate. Ifthe reflux rate is too high, the condenser becomes over- leaded with vapor. The condenser is not able to______ the vapor quickly enough 87 pump efficiency increase lowdown control ‘condenser water ‘condenses reflux reflux condense418 419, 420, 421 422, 423, 424, 428, 426, 427. 428, 429, 490, The excess of vapor causes a pressure buildup in the ‘To correct this, the reflux rate must be { increased / reduced | Too much —__ functioning condenser. I the condenser is not transferring heat effectively from ‘the vanor tothe cooling water, tne vapor will no condense, ‘An overload of vapor will Build up pressure in the over- head vapor line and in the itself. can also be caused by a mal- ‘A fouled condenser is often indicated by a pressure increase ‘on the water side or a water outlet temperature that is 00 (high / tow Ifthe condenser is fouled by debris accumulating at the tubesheet, tne debris can be loosened by backtlowing the cooling Itis possible hat other maintenance must be performed depending on the nature of the — Changes in pressure and tempereture on the water side may also indicate problems with the supply. ‘Condenser malfunction may also be caused by air in the ‘cooling water systom, ‘Ar causes vapor binding, which reduces the efficiency with which heat is —— To help eliminate vapor binding, a provided in the water exit line Noncondensibie vapors in the process sce ofthe exchanger ccanalso cause a buildup in the fracion- ator. Because the vapors do not condense, they take up surface area in the exchanger. Aloss in surface area causes a loss in the capacity ofthe exchanger ‘This can be corrected by venting the process side of the exchanger to release the noncondensible Refer to Exhibit 10 for trames 491-460, 431, Exhibit 10shows the layoutofasystem involvinga furnace, 4 reacior, two primary heat exchangers, one secondary heat exchanger, two rebollers, and a 58 {ractionator, or tower reduced pressure condenser low fouling water ‘exchanged, or transferred vent pressure cooting condenser432, 433, 434, 495, 436. 437. 438, 439 440, 441 442, 443. 445, 446, ‘Tho feed to this system consists of hydrogen and low octane gasoline. High octane gasoline ithe —_ ‘The reaction which raises the octane rating of the gaso- line takes place in the ‘A temperature of 1000°F. is necessary for this reaction ‘The heat to maintain this temperature is provided by the ‘The reaction is promoted by the use of a ‘Trace the path ofthe product stream in Exhibit 10 ‘The product leaves the reactor, flows through the second ary exchanger, through two reboilers, through two primary ‘exchangers, andfinally passes through the. ‘When the product high octane gasoline, leaves the reactor, itstemperatureis_°F. But, when the product leaves the condenser, its tempera ture has dropped to___°F. In other words, the system of exchangers, reboilers, and ‘condenser is used to — the product stream. Now trace the path of the feed stream. ‘The feed leaves the pump and passes through the primar exchangers, the ____ and the reactor. During this process, the feed a large part ofthe heat given up by the product stream. ‘The product cooling system is used to pre-__ the feed. ‘Some of the heat is also transferred through the to other processes. Because heat is recaptured in the system, the furnace uses less. The cooling problem is also simplified, Altogether, the entire process is ( more / less } efficient and economical. First, the operator should check temperatures at various points along the system. IU the furnace inlet temperature is stable at 700°F, but the ‘outlet temperature is below the 1000°F control point, the problem is probably in the 58 product reactor furnace catalyst condenser 950 100 furnace absorbs heat rebollers more furnace47. 448. 449, 450. 451 452, 454, 455, 456, 457, 458, 459, 460, ‘The by-pass valve also controls the amount of heat avail able to the rebollers. When the by-pass is closed and a maximum amount of hheat is transferred to the feed stream through the second- ary exchanger, the temperature of the product stream (decreases / increases ) Therefore, (less / more ) heat is available to the rebollers, There is also loss he exchangers, 3 available to the —_ Because ofthis, when readjusting the by-pass fo get maxi mum heat tothe feed stream, the operator mus take care ‘to maintain the necessary heat input to the ——_ ‘Another cause for difficulty in maintaining the 1000°F ‘control point might be an overload on the reboilar. ‘Too much heat is being transferred through the to the stream that leads outside the system ‘To correct this, the operator should ( reduce / increase } the load on the reboilers. Uf, however, the inlet temperature has dropped below the 700°F level, the problem may lie in the by-pass valve or the exchanger load. ‘The Valve controls the flow of the product stream through the —_____ exchanger. If the by-pass valve is completely closed. (all / some ) of the product stream will pass through the exchanger. Inthat case, @ maximum amount of heat willbe transferred tothe stream It the by-pass valve is completely open, most of the prod ct stream will bypass the secondary exchanger. Therefore, a minimum / maximum ) amount of be transferred to the incoming feed stream. 3 wil When less heat is being transferred to the feed stream through the secondary exchanger. the temperature of the feed stream at the _____ inlet drops. it decomes difficult for the __ to raise the {feod stream temperature tothe necessary 1000°F. ‘Therefore, a drop in feed temperature at the furnace inlet might be caused by a by-pass valve that is too far ( open / closed ) ‘To correct ths, the operator should readjust the 60 primary reboilers reboilers reduce secondary all feed furnace furnace open by-pass