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Troubleshooting Shell-And-Tube Heat Exchangers: Use These Techniques and Guidelines To Ensure More Reliable Heat Transfer
Troubleshooting Shell-And-Tube Heat Exchangers: Use These Techniques and Guidelines To Ensure More Reliable Heat Transfer
heat exchangers
t is stressful when exchangers go online and don't per 5. Have any warnings been ignored in the heat
~
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Bubble flow "
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Wave flow
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Stratified flow
\ Fig. 3. Bad design that traps out condensate.
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Excess surface problems. In the design stage, the clean
~m
w
~~ .02 \ condition may not have been evaluated. Many exchang
ers are designed for fouled conditions only. Most of the
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.01 r\ time this is all that is necessary. However, in some situa
.1 .2 .3.4 .6.8 1 2 3 4 6 8 10 20 3040 tions the clean condition must be checked. More exchanger
VSG Superficial gas velocity, fUsec oversurface means more deviations from outlet design
temperatures and a greater potential for problems.
Fig. 2. Map of stratified flow showing limits. For high-temperature applications, the outlet temper
ature of the heated stream must be checked. It will be
higher than the process design temperature. If this tem
when the bundle is removed and later re-installed. perature is higher than what was used to select the met
A pressure drop that is too high can be caused by: allurgy, there may be a problem. Small 5 relates a case
• Improper venting where the effect of oversurface and the clean condition
• High fouling was not checked. It resulted in ruptured tubing and the
• Debris from startup loss of tube fins. Another problem with higher-than-pro
• Freezing of the process stream cess-design outlet temperatures is that a liquid may
• Slug flow for two-phase streams degrade or lose its thermal stability. For cold applications,
• Fabrication problems. the outlet temperature of the stream to be cooled must be
Improper or no venting causes a high pressure drop. checked. It can cause stream freezing and tube plugging.
This should be one of the first items to check if there is a It can also cause brittle tubing and tube failures.
high pressure drop. This usually occurs in condensers and Another case where excess surface can be a problem is
is discussed more fully in a later section. in vaporizer design. If vaporizing is done too well, there
will be surging of vapor leaving the exchanger. As a young
Fouling. If there is a gradual decline in heat transfer, engineer, I saw an ammonia vaporizer in a nitric acid plant
fouling may be the culprit. Heat exchanger software can creating surging vapor to the reactor. All the liquid would
give the available fouling as compared to design fouling. flash to vapor inside the kettle; liquid feed would then
Sometimes fouling is so severe that tubes can be plugged surge in and flash again. Our process group determined
inside or the shellside ligaments between the tubes can there was excess surface and plugged off some tubes. The
be filled. This is sometimes seen when bundles from a kettle operation smoothed out and reactor efficiency
refinery are sent to be repaired. Actual fouling can be improved.
much higher than the TEMA CThbular Exchanger Man Excess surface problems are cured by plugging tubes
ufacturer's Association) specification. 3 in the inlet channel. There are many different types of
If you suspect that fouling is a problem, check the plugs, but metal plugs with a slight taper are most com
exchanger's operating history. Are there deviations from mon. Unless the temperatures are high, wooden plugs can
design conditions? Are there periods of operation where be used in a pinch.
flows are lower than design? Heat exchangers will foul
faster at low velocities. If water fouling is a problem, have Venting. Proper venting is a startup necessity. Improper
the water flows been cut back in the winter? venting usually occurs on startup and is recognized by
If you determine that fouling is a problem, make a chem poor heat transfer and a high pressure drop. Exchangers
ical analysis of the fouling material. Knudson 4 discusses dif operating under a vacuum can be more of a problem than
ferent fouling control methods and types of cleaning. Online those operating under pressure. The vacuum will suck air
and offline mechanical cleaning plus chemical cleaning is into the exchanger if it isn't perfectly sealed. Vents should
discussed. If the fouling cannot be controlled, a tube elec be located at the exchanger's highest points. The shell
tropolishing process can slow scale and other buildup. It side is especially vulnerable to pockets of air or noncon
eliminates small ridges and pits that contribute to fouling. densables. Gas can get trapped at the bundle~s top or by
"ears" at the top of baffles. If a venting problem is sus
Debris. Check to see if there is a strainer in the piping pected, talk to operations about their startup procedures.
ahead of the inlet nozzles. If there is no strainer, there Fijas 6 recommends startup procedures. YokelF has a more
may be debris in the exchanger. It is amazing what types complete discussion of vents, especially vertical fixed tube
of debris can be found in heat exchangers after startup sheet exchangers.
such things as rocks, trash, wrenches, gloves, weld rods,
clothing, pencils, etc. Possibly during a work force shift TWo-phase heat transfer. Proper venting is especially
change, the first shift left something that the second shift important for two-phase streams. In addition to air that
did not see before closing the piping. may be introduced during startup, noncondensable gases
92 HYDROCARBON PROCESSING / SEPTEMBER 1996
1 I
/
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Flow ~ ~ f-
r( f-
,.
Fig. 4. Baffle cut that holds a condensate liq Fig. 5. A large nozzle/shell size ratio can Fig. 6. Channel design that causes bad flow
uid level. restrict entrance or exit area. distribution.
can come from the process. These If the flow pattern is stratified flow liquid condensate flows freely out of
gases occur most often in condensers. or wave flow and it is boiling, the the tubes. A sulfur condenser is an
Vents on horizontal condensers should heat-transfer surface needs to be sub extreme example. The operating pres
be located at the opposite end from the merged so only liquid is in contact sure is low, it has one tube pass and
inlet. This is such a problem on the with the tubing. This is accomplished the viscous sulfur does not flow freely.
condensing steam side of feed water using a weir for kettle reboilers. In Shellside baffles can also act as
heaters that they have startup and other exchanger types, this can be dams. Horizontal-cut baffles should
operating vents. done using an external pipe loop or, not be used in most condensing
Common problems with two-phase if feasible, raising the exchanger to a streams. Vertical-cut baffles can be
streams are stratified flow and wave vertical position. In this case, the used, but make sure that small baf
flow. The exception is pool boiling in lower thermal-conductivity vapor is fle cuts do not flood too much of the
a kettle. An illustration of stratified in the form of bubbles and higher bundle. Fig. 4 shows how small baf
flow is in Fig. 1 where there is little thermal-conductivity liquid coats the fle cuts can create a liquid level. The
mixing of the liquid and vapor. Vapor, tube surface. worst case is when the condenser has
with its lower thermal conductivity, If there is condensing, no bubbling a low operating pressure and the con
blankets some of the exchanger sur action thins the liquid film. The liquid densate has a natural hydraulic level
face and reduces its film coefficient. film needs to be thin for good heat lower than what the baffle cut sub
This type of flow can greatly lower the transfer. One cure for tubeside con merges.
overall heat-transfer coefficient. densing is to use inserts that give the Just because superheated steam is
In one case, a manufacturer designed fluid a higher velocity and a swirling the heating medium does not mean
a cryogenic exchanger for an over action to thin the liquid film. Another hotter steam is better. A high amount
all rate of approximately 35. The solution is to raise the exchanger to of superheat is not much of a problem
exchanger was not checked for strati a vertical position and condense at high operating pressures. However,
fied flow and the tubeside had a low downward. at low operating pressures the mass
velocity. When the overall rate was Another possible problem with con velocity will be low and the gas heat
back-calculated from the operating densing is holding up condensate flow. transfer in the desuperheat zone will
temperatures, it was only 6.9. Appar This thickens the liquid film so that be low. So, more superheat causes a
ently, most of the inside tube surface part of the heat exchanger surface bigger problem. More of the exchanger
was in contact with gas only. acts as a liquid cooler with lower heat surface will be in contact with dry
Fig. 2 can be used to check for strat transfer. A steam trap is an example steam with its low heat transfer.
ified or wave flow. 8 Calcu]ate the gas of a device that keeps condensate Film boiling can be a problem if the
velocity and liquid velocity as if each is moving. It does not allow condensate hot fluid temperature is much higher
alone (superficial velocity). Stratified to build up a thick film. Fig. 3 shows than the boiling stream temperature.
flow exists and there is a bad flow pat an example of bad tubeside nozzle The bubbling action can be so violent
tern for two-phase heat transfer if the location for a condensing stream. that only vapor contacts the exchanger
liquid velocity is less than 0.5 ftlsec Tubeside condensate can build up in tubing. In this case, the critical heat
and the gas velocity is below the cal the heat exchanger's lower part. The flux is exceeded. For hydrocarbons
culated value from: outlet channel acts as a dam or weir that are steam-heated, maximum
Max V:sg = 3.5/(VsZ )1I2 to the condensate. temperature drop across the boiling
The cure for stratified flow and Another case of condensate flow film is approximately 80°F to 100°F.
slightly wavy flow is to keep dry gas hold-up and low heat transfer is when This corresponds to a mean tempera
away fl'om the tubewall. If the stream there is one horizontal tube pass and ture difference of approximately 150°F.
inside the tubes has low fouling char the operating pressure is only slightly This is cured by reducing the steam
acteristics, twisted tape inserts can be above atmospheric. There is not pressure.
used to swirl and mix the fluid. This enough driving force to keep the con Poor thermo syphon performance
insert type is available from some heat densate flowing well. This condenser can be caused by an incorrectly set
exchanger companies. type should be sloped enough so the tower liquid level. There needs to be
94 HYDROCARBON PROCESSING I SEPTEMBER 1996
Flow
A.
"
"
Flow
Ie !
"
I I
to t
Fig. 8. A) Normal split flow pattern; 8) One end closed of long baf
fle by mistake.
ing in flow bypassing the tubes. The second and third passes The author
were starved for flow. This situation can occur when gaskets Dale Gulley is president of Gulley Computer
Associates, a corporation he founded in 1966
and gasket grooves have a nonsymmetrical pattern. that specializes in heat exchanger design and
consulting. They provide software for heat
Field mistakes. In one instance, a heat exchanger was exchanger design and process calculations. Mr.
piped up backwards. The fluid that should have been on Gulley has heat exchanger and software devel
opment experience that spans 40 years and has
the shells ide was piped to the channel side and vice versa. previously published articles in Hydrocarbon Pro
When both streams are in turbulent flow, this switch may cessing. He is a chemical engineering graduate from Oklahoma
go unnoticed. In this case, fluid that shouM have been in State University. Mr. Gulley is a director of the Tulsa Science Foun
the shell was semiviscous. On the shellside, the fluid would dation and a member of AIChE and ASME. He is a registered pro
fessional engineer in Oklahoma.
have been turbulent and given better heat transfer. When
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98 HYDROCARBON PROCESSING I SEPTEMBER 1996