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Suez University Faculty of Petroleum & Mining Engineering: Prepared by
Suez University Faculty of Petroleum & Mining Engineering: Prepared by
/Prepared by
Student/ Mohamed salah abou El_hamed
Department/ petroleum refining
Year/ third
specifically designed for the efficient transfer of heat from one fluid to another fluid
over a solid surface.
But yet, since double pipe heat exchangers are simple, they are used to teach heat
exchanger design basic to students and as the basic rules for modern and normal heat
exchangers are the same,
students can understand the
design techniques much easier.
To start the design of a double
pipe heat exchanger, the first
step is to calculate the heat duty
of the heat exchanger.
Another type of heat exchanger is the plate heat exchanger. One is composed of
multiple, thin, slightly separated plates that have very large surface areas and fluid
flow passages for heat transfer. This stacked-plate arrangement can be more
effective, in a given space, than the shell and tube heat exchanger.
2. Countefflow Exchanger
In this type, as shown in, the two fluids flow parallel to each other but in
opposite directions, and its temperature distribution may be idealized as one-
dimensional.
Ideally, this is the most efficient of all flow arrangements for single-pass
arrangements under the same parameters. Since the temperature difference
across the exchanger wall at a given cross section is the lowest, it produces
minimum thermal stresses in the wall for equivalent performance compared to
other flow arrangements.
In certain type of heat exchangers, counterflow arrangement cannot be
achieved easily, due to
manufacturing
difficulties associated
with the separation of
Tube diameter: Using a small tube diameter makes the heat exchanger both
economical and compact. However, it is more likely for the heat exchanger to foul
up faster and the small size makes mechanical cleaning of the fouling difficult. To
prevail over the fouling and cleaning problems, larger tube diameters can be used.
Thus to determine the tube diameter, the available space, cost and the fouling
nature of the fluids must be considered.
Tube thickness: The thickness of the wall of the tubes is usually
determined to ensure:
Tube length: heat exchangers are usually cheaper when they have a smaller
shell diameter and a long tube length. Thus, typically there is an aim to make the
heat exchanger as long as physically possible whilst not exceeding production
capabilities. However, there are many limitations for this, including space available
at the installation site and the need to ensure tubes are available in lengths that are
twice the required length (so they can be withdrawn and replaced). Also, long, thin
tubes are difficult to take out and replace.
Tube pitch: when designing the tubes, it is practical to ensure that the tube
pitch (i.e., the centre-centre distance of adjoining tubes) is not less than 1.25 times
the tubes' outside diameter. A larger tube pitch leads to a larger overall shell
diameter, which leads to a more expensive heat exchanger.
Tube corrugation: this type of tubes, mainly used for the inner tubes,
increases the turbulence of the fluids and the effect is very important in the heat
transfer giving a better performance.
Tube Layout: refers to how tubes are positioned within the shell. There are
four main types of tube layout, which are, triangular (30°), rotated triangular (60°),
square (90°) and rotated square (45°). The triangular patterns are employed to give
Having baffles spaced too closely causes a greater pressure drop because of flow
redirection. Consequently having the baffles spaced too far apart means that there
may be cooler spots in the corners between baffles. It is also important to ensure
the baffles are spaced close enough that the tubes do not sag. The other main type
of baffle is the disc and donut baffle, which consists of two concentric baffles. An
outer, wider baffle looks like a donut, whilst the inner baffle is shaped like a disk.
This type of baffle forces the fluid to pass around each side of the disk then through
the donut baffle generating a different type of fluid flow.
Fixed tube liquid-cooled heat exchangers especially suitable for marine and harsh
applications can be assembled with brass shells, copper tubes, brass baffles, and
forged brass integral end hubs.
2. Tube Sheets
Tube sheets usually constructed from a round, flattened sheet of metal. Holes for
the tube ends are teen drilled for the tube ends in a pattern relative to each other.
Tube sheets are typically manufactured from the same material as tubes, and
attached with a pneumatic or hydraulic pressure roller to the tube sheet. At this
point, tube holes can both be drilled and reamed, or they are machined grooves
(this significantly increases tube joint strength).
The tube-hole pattern, often called ‘pitch’, varies the distance between tubes as
well as the angle relative to each other allowing the pressure drop and fluid
velocities to be manipulated in order to provide max turbulence and tube surface
contact for effective heat transfer.
Tube and tube sheet materials are joined with weld-able metals, and often further
strengthened by applying strength or seal weld to the joint. Typically in a strength
weld, a tube is recessed slightly inside the tube hole or slightly beyond the tube
sheet whereas the weld adds metal to the resulting edge. Seal welds are specified
when intermixing of tube liquids is needed, this is accomplished whereas the tube is
level with the tube sheet surface. The weld fuses the two materials together, adding
no metal in the process. When it becomes critical to avoid the intermixing of fluid, a
second tube sheet is designed in. In this case, the outer tube sheet becomes the
outside the shell path, and the inner tube sheet is vented to atmosphere, so that a
fluid leak can be detected easily effectively eliminating any chance of cross
contamination.
3. Shell Assembly
The shell is constructed either from pipe or rolled plate metal. For economic
reasons, steel is the most commonly used material, and when applications
involving extreme temperatures and corrosion resistance, others metals or
alloys are specified. Using off-the-shelf pope reduces manufacturing costs and
lead time to deliver to the end customer. A consistent inner shell diameter or
‘roundness’ is need to minimize the baffle spacing on the outside edge,
excessive space reduces performance as the fluid tends to channel and
bypasses the core. Roundness is increased typically by using a mandrel and
expanding the shell around it, or by double rolling the shell after welding the
longitudinal seam. In some cases, although extreme, the shell is cast and then
bored.
When fluid velocity at the nozzle is high, an ‘impingement’ plate is specified to
distribute fluid evenly in the tubes, thereby preventing fluid-induced erosion,
vibration and cavitation.
4. Bo
nnets and End Channels
Bonnets / end channels regulate the flow of fluid in the tube-side circuit, they are
typically fabricated or cast. They are mounted against the tube sheet with a bolt
and gasket assembly; many designs include a ‘machine grooved’ channel in the
tube sheet sealing the joint.
If one or more passes are intended, the head may include pass ribs that direct flow
through the tube bundle (figure C). Pass ribs are aligned on either end to provide
effective fluid velocities through an equal number of tubes at a time ensuring a
constant, even fluid velocity and pressure drop throughout the bundle.
Figure
C. Heads
contain
pass
ribs
that
direct
flow on
the tube-
side fluid for one or more passes across the tube bundle.
The material used in the cast bonnets / heads used in smaller diameters (ie 15” or
less) are typically, poured from iron, steel, bronze, Hastelloy, nickel plated, or
stainless steel. Pipe connections are normally NPT, others including SAE, tri-clamp,
ASME flanged, BSPP, and others types are available.
5. Baffles
Baffles function in two ways, during assembly they function as tube guides, in
operation they prevent vibration from flow induced eddies, last but most
importantly they direct shell-side fluids across the bundle increasing velocity and
turbulence effectively increasing the rate of heat transfer.
All baffles must have diameter slightly smaller than the shell in order to fit,
however tolerances must be tight enough to avoid a performance loss as a result of
fluid bypass around the baffles. This is where the concept of ‘shell roundness’ is of
up most importance in sealing off the otherwise would be bypass around the
baffle.
In typical liquid applications, baffles occupy between 20-30% of the shell diameter;
whereas in a gas application with a necessary lower pressure drop, baffles with 40-
45% of shell diameter are used (figure D). Baffle placement requires an overlap at
one or more tubes in a row to provide adequate tube support.
Figure C. Heads contain pass ribs that direct flow on the tube-side fluid for one or
more passes across the tube bundle.
In a 'single-segmental’ configuration, baffles move fluid or gas across the full tube
count. When high velocity gases are present, this configuration would result in
excessive pressure loss thus calling fourth a ‘double-segmental’ layout. In a
‘double-segmental’ arrangement, structural effectiveness is retained, yet allowing
gas to flow in a straighter overall direction. While this configuration takes full
advantage of the full available tube surface, a reduction in heat transfer
performance should be expected.
INFORMATION COLLECTION
Besides the obvious process information of flow, temperatures and pressure drops,
you win probably need the manufacturer's heat exchanger drawings. Hopefuny, you
will not have to run heat exchanger tests. But if you do, there are procedures in the
literature.1, 2
Using the collected process information, make a full thermal design computer run.
The printout will have much more information than a standard specification sheet.
Check the printout with the following in mind:
1. Are there any error messages about the physical properties used?
2. Are there error messages for the input data?
3. Check the section that analyzes the design for comments. This is a section of the
program that acts as expert system software.
4. Was the correct heat-transfer type specified on input?
2. Debris.
Check to see if there is a strainer in the piping ahead of the inlet nozzles. Ifthere is no
strainer, there may be debris in the exchanger. Itis amazing what types of debris can
be found in heat exchangers after startupsuch things as rocks, trash, wrenches,
gloves, weld rods, clothing, pencils, etc. Possibly during a work force shift change, the
first shift left something that the second shift did not see before closing the piping.
4. Venting.
Proper venting is a startup necessity. Improper venting usually occurs on startup and
is recognized by poor heat transfer and a high pressure drop. Exchangers operating
under a vacuum can be more ofa problem than those operating under pressure. The
vacuum will suck air into the exchanger ifit isn't perfectly sealed. Vents should be
located at the exchanger's highest points. The shellside is especially vulnerable to
pockets of air or noncondensables. Gas can get trapped at the bundle~s top or by
"ears" at the top of baffles. Ifa venting problem is suspected, talk to operations
about their startup procedures. recommends startup procedures. YokelF has a more
complete discussion ofvents, especially vertical fixed tube sheet exchangers.
5. Field mistakes.
In one instance, a heat exchanger was piped up backwards. The fluid that should
have been on the shells ide was piped to the channel side and vice versa. When both
streams are in turbulent flow, this switch may go unnoticed. In this case, fluid that
shouM have been in the shell was semiviscous. On the shellside, the fluid would
have been turbulent and given better heat transfer. When on the tubeside, the fluid
flowed in the transition region between turbulent and viscous. This gave a
noticeably lower heat transfer, although better heat transfer than calculated .