Speaker : 9:00 Introduction

Mr. Byron Black Hairpin Heat Exchanger Fundamental

Product Manager and
Director of Sales for Asia • What is Hairpin Heat Exchanger
• Specifications & Standards
• Product Applications
11:30 Q&A
13:00 Enhancements for Hairpins & case studies
Inspection & Maintenance
14:30 Upgrading
• Twisted Tube
• Special Products : Tank Heating
15:30 Q&A

Original brand/Trade mark :

inCyam Co.,Ltd. is a company under BE Petrothai Group
ALCO® BAS-TEX
BOS-HATTEN® and KHT Authorized Distributor in Thailand
www.bepetrothaigroup.com
Hairpin Heat Exchangers
…and other Koch Heat Transfer technologies

By

Byron Black – Product Manager

18th November 2015

Rayong, Thailand

Introduction

1
 Koch Industries

Koch Headquarters, Kansas

 We are part of Koch Industries. A subsidiary of Koch Chemical Technology Group.

 Koch Industries is based in Wichita, Kansas, and is one of the largest private
companies in America.*

* According to Forbes

Koch Industries

 Koch Industries has historically reinvested 90% of earnings back into its business.
 Since 2003 Koch Industries has invested about $65 billion in acquisitions and other
capital expenditures.
 More than 100,000 employees worldwide in about 60 countries

2
 Combustion Heat Exchange Separating & Mixing Corrosion Control Gas Plants

Koch Heat Transfer: Origins

1939 Founded by John Brown. Invents and patents method of welding fintubes.
1940’s BFT starts double pipes and tank heaters. BFT fintubes used for fuel heating
of Navy’s Liberty Ships for World War II.
1950’s BFT Canada founded in Ontario, Canada.
1960’s Opens office in Mexico and France (BFT France opens in Thonon-Les-Bains).
BFT estimator R.W. “Dick” Holland, leaves and forms R.W. Holland Co.
1969 BFT moves to Tulsa, to join Western Supply Co
1970’s Hagner and Crouch buy BASCO and creates BAS-TEX in Houston.
1980’s Bas-Tex buys BFT and merges in Houston. Brown Fintube Company
is the surviving name.
1990’s BFT France sold to Hamon. No longer a part of BFT USA.
KOCH acquires BFT. Begins TWISTED TUBE™ Exchangers.
2000’s BFT acquires Industrie Meccaniche Di Bagnolo - IMB™ (sold in 2015).
BFT acquires ALCO and Bos Hatten in early 2015.

3
 Koch Heat Transfer Locations

Houston, Tx Toronto, Canada

• KHT fully owned design and manufacturing locations:
 Houston, TX – USA (Headquarters, design & manufacture)
 Toronto, ON - Canada. (manufacture)
 Buffalo, NY – USA (design)

• KHT global ad-hoc manufacturing capability.

• Korea, Germany, Italy.

Koch Heat Transfer Locations

Calgary
Toronto
Italy

Houston

Singapore

Sao Paulo

4
 Our Products
Shell & Tube / Tubular Heat Exchangers & Enhanced
Heat Transfer:
• Multi-Tube Hairpin & Double-Pipe Heat
Exchangers. (with TAPER-LOK® closure)
• TWISTED TUBE® Heat Exchanger Technology.
• Tank and Suction Heaters
• Tube Inserts technology

KCTG Research & Development Facility

KHT Test Rigs for S&T Hex
• World class heat
transfer R&D
facility.
• Separate tube-side
and shell-side rigs
provide the ability
to evaluate thermal
performance of
enhanced tubes
and enhanced tube
bundles over a
wide range of
operating and
design variables.

5
KCTG Research & Development Facility
KHT Test Rigs for S&T Hex
World class heat
transfer R&D
facility.
Separate tube-side
and shell-side rigs
provide the ability
to evaluate thermal
performance of
enhanced tubes
and enhanced tube
bundles over a
wide range of
operating and
design variables.

Hairpin Heat Exchanger Fundamentals

6
KHT: many years experience in Hairpin Technology

BROWN FINTUBE® Hairpin Heat Exchangers

7
What is a hairpin?

Simply put: A single pass shell & tube in counter current flow
folding in half (i.e. u-configuration).

Counter-current flow maximizes temperature difference

8
 Fundamental Heat Transfer Equation
Q= U0 . A0 . ∆Tm

Fundamental Heat Transfer Equation

Q= U0 . A0 . ∆Tm

Increase Area (A0) = Increases duty (Q)

Increased surface area allows duty to be maintained whilst

reducing temperature difference (∆Tm)

9
 Log Mean Temperature Difference
• Temperature difference is the driving force for heat
transfer.
• LMTD is a measure of the difference in temperature
between hot and cold streams.
• This temperature difference varies throughout the
exchanger.
• We use LMTD to cover the range.
ΔT2

ΔT1

How is LMTD Calculated?

FOR INTERNAL USE ONLY

10
 Co-current Flow
• An exchanger is in co-current flow when the streams are
flowing in the same direction as each other.

Counter-current Flow
• An exchanger is in counter-current flow when the
streams are flowing in opposite directions of each other.

11
 F Correction Factor
• LMTD assumes flow direction for both streams is
consistent throughout exchanger(counter-current or co-
current).
• When there is more than one tube side pass, a correction
factor is needed.
• F correction factors for various exchanger configurations
are found in standard textbook charts and equations.

Consider a Hairpin when:

• A temperature cross exists or close temperature

approach is desired
• High pressure applications exist (up to 15,000 PSI)
• Cycling and thermal shock conditions are present.
• High terminal temperature differences exist.
• Avoidance of an expansion joint.
• Ability to clean u-tubes is required.
• All external bolting is desired.
• An augmentation device would improve heat transfer.

12
 Advantages of Hairpin vs Shell & tube

Separate vs Common terminal closures

• Common: terminal temperatures applied to same

tubesheet, bolting and gasket. Can result in leakage
when large terminal tubeside temperature differences
exist.

13
 Separate vs Common terminal closures

• Separate: independent terminal tubeside and shellside

closures address applications with high terminal temperature
differences and/or thermal shock conditions.
• Separate closures result in smaller flanges, thinner tubesheets and
smaller bolts in high pressure applications

Thermal Expansion Considerations

• Expansion joints or expansion bellows are often used.

• These devices are often thinner than shell and prone to damage
during fabrication, shipping & handling and operation.

14
 Thermal Expansion Considerations

• All expansion takes place at the back end of the exchanger

eliminating the need for such devices.
• Eliminates need for expansion joints or bellows

Hairpin vs. `F’ bundle

• `F’ shell requires long baffle with seal strips that seal
against the shell id. These are thin flexible metal that are
easily damaged and can result in bypass.
• Can cause thermal leakage between the shell passes

15
 Hairpin vs. `F’ bundle

• Counter current flow in separate shell legs eliminates need for

leaf seals and eliminates thermal leakage.

Shell & Tube u-bundle with tight radius u-bends

• U-tube shell and tubes typically have tight u-bend radii on the
inner rows making them difficult to clean.
• Temperature differences can result in different expansion rates
between the tube passes causing stress on the tight u-bends.

16
 Hairpin with large radius u-bends

• Large radius u-bends facilitate thermal expansion and cleaning

more so than shell & tube u-tube designs.

`E’ shell with fixed supports and sliding plates

• Excessive shell expansion or contraction can add additional

stresses on the shell nozzles.

17
 Hairpin sliding supports & connections on one side

• Same end nozzle location minimizes thermal stresses on piping

unlike shell & tube single pass shell configurations

Internal vs External bolting

• Unlike
Hairpins have allfloating
hairpins, connections on the
head shell & same end, thus
tube designs usesuch
internal
stresses arecontacts
bolting that minimized the shellside fluid and cannot be tightened
while in operation

18
Hairpin Heat Exchanger Components

Components: Nomenclature
RETURN END SHELLSIDE NOZZLE FRONT CLOSURE TYPE
CONSTRUCTION ARRANGEMENT & TUBESIDE CONNECTION
A B A A B

Removable Bonnet Fixed 180 ° Separate Sealed-Lok- Separate Sealed-Lok -

Return H ousing Flange without Reducer * Flange with Reducer
C D C D

Standard Shell Arrangement

Removable bonnet Separated Head Separated Head Taper-

Fixed Dome With Nozzle Intermediate / Lok®
Low Pressure High Pressure *
E F B E F

Fixed Dome
With Nozzle
Rod-Through with
Fixed Tube Fixed Tube
Pack ed Joint
Bolted Tubesheet Bolted Flange
G G H

Parrallel Flow Arrangement

(Dual Inlet / Outlet Shell Nozzles)

Fixed Tube Fixed Tube

Rod-Throu gh with Expansion Joint Taper-Lok® Flanged * Reducer with Flange
H C J

Rod-Throu gh Single bolted with Expansion Joint ZR Closure *

I * Available with Flanged Connections

Rotated Nozzle Shell Arrangement

(Shell N ozzles Rotated 90 Degrees)

Taper-Lok® Round Bonnet

19
 Closure Types

Separated-Head Double-pipe Medium-pressure Separated-Head

High-pressure TAPER-LOK® CLOSURE Separate Sealed LOK-FLANGE ®

TAPER-LOK® is a registered trademark of Taper-Lok Corporation

Closure Types

Severe Service Separated Head Heavy Duty Separated Head

(Common Bolting)

20
 Separated Head

Through bolting with external split ring

Closure Types

Threaded flange and internal split ring

21
 TAPER-LOK® CLOSURE

High Pressure Closure

TAPER-LOK® CLOSURE

By combining our patented external split flange shell closure with our patented
pressure energized TAPER-LOK® Closure tube closure, KHT has provided the
market with the most reliable, easily cleaned and inspected high pressure heat
exchanger available.

22
 Return End Bonnet Closure

Return End Bonnet Closure is a compact through bolted

design. When the bonnet is removed, the u-bends of the
tubes are completely exposed to permit full field
inspection. The full floating u-tube bundle compensates
for the differential shell-tube expansion.

Large Multi-tube Return Bend Closures

Fabricated elliptical bonnet All welded non-removable return

Round TAPER-LOK® Closure Bonnet

23
 Hairpin Industry Standards

Unlike TEMA, nomenclature, model numbers and closure

technology for hairpin heat exchangers are unique to each
manufacturer.

Current or standards
• API 663
• ISO 12212
• Both address design standards
and nozzle loading.

Shell and Tube Heat Exchangers

• TEMA size is designated by nominal ID (mm) and nominal length (mm)
(e.g. 1250-6096 type AEU).
• TEMA heat exchanger types (source: www.tema.org): Table
• General construction features (source: www.tema.org): Features
• Standard TEMA data sheet (source: www.tema.org): Data Sheet

Source: Koch Heat Transfer

24
 Hairpin Case Study

Hairpin Case Study

Typical applications

 Feed / effluent
 Compressor coolers
 Lean / rich systems (TEG and Amine)
 Offshore gas coolers
 Flow line heaters
 Fuel gas heaters

25
 Hairpin Case Study

1) Export Gas Compressor

2) Discharge Cooler
3) Gas / Gas Exchanger
4) Gas / Liquid Exchanger
5) Fuel Gas Superheater

Weight Footprint Cost

HP S&T HP S&T HP S&T

Export Gas Comp. Disc. Cooler 0,27 1 0,55 1 0,69 1

26
 Biggest hairpins ever built
(North Sea)

Weight Footprint Cost

HP S&T HP S&T HP S&T

Gas / Gas Exchanger 0,4 1 0,9 1 0,83 1

27
 Weight Footprint Cost

HP S&T HP S&T HP S&T

0,34 1 0,47 1 0,83 1

Weight Footprint Cost

HP S&T HP S&T HP S&T

0,34 1 0,34 1 0,84 1

28
 Fuels Gas Preheaters

Benefits of Hairpin Technology

Weight (lb) Footprint (sq ft) Cost

HP S&T HP S&T HP S&T

Export Gas Comp. Disc. Cooler 63,000 234,000 266 486 $249,450 $360,000

Gas / Gas Exchanger 55,800 138,000 288 315 $174,000 $210,000

Gas / Liquid Exchanger 21,000 61,000 84 177 $87,500 $105,000

Fuel Gas Superheater 40,300 120,000 113 330 $159,000 $190,000

180,100 553,000 751 1,308 $669,950 $865,000

SAVINGS 372,900 557 $195,050

29
 Enhancements For Hairpins

Fundamental Heat Transfer Equation

Q= U0 . A0 . ∆Tm

Increase Area (A0) = Increases duty (Q)

Increased surface area allows duty to be maintained whilst

reducing temperature difference (∆Tm)

30
Fundamental Heat Transfer Equation
Q= U0 . A0 . ∆Tm

Increase Area (A0) = Increases duty (Q)

For new installations, we design to reduce `A’ to meet a

specified `Q’.

For retrofits, we design to increase Q by affecting the

`Uo’, the `A’, the LMTD or all three.

Overall Heat Transfer Coefficient

• The overall heat transfer coefficient (UO) depends on:
• Individual film coefficients
• Fouling resistances (fouling factors)
• Thermal conductivity and thickness of the metal tube
wall (in S&T)

31
 Uo=1/[(1/ho+ro)+rw+ ri(Ao/Ai)+1/hi(Ao/Ai)]

•ho=clean shellside rate

•ro=shellside fouling resistance factor
•rw=tube wall resistance
•ri=tubeside fouling resistance factor
•Ao/Ai=outside to inside surface of tubing
•hi=clean tubeside rate

Current Status

Industry largely relies on conventional, segmental baffle,

shell-and-tube (S&T) heat transfer technology

32
 Weakness of Plain Tube,
Segmental Baffle, S&T heat exchangers

 Limited Thermal Effectiveness (<0,7 or less with multi-pass)

 Minimum Temperature Approach (5 °C)
 Relatively low pressure drop/heat transfer conversion
 Far-from-ideal fluid dynamic conditions
 Two-phase adverse phenomena under certain conditions

and therefore…
 High capital costs and large dimensions are required to push
limits of heat transfer

Weakness of Plain Tube,

Segmental Baffle, S&T heat exchangers

 Passive pressure drop components (momentum losses)

 Uneven flow distribution: low velocity areas, dead spots,
hot/cold spots.
 Flow Induced Vibration (FIV): Damage tubes, baffle fret.
 Strong negative influence of shell side bypass streams and
eddies on EMTD, more evident when high thermal
effectiveness is required

33
Shell Side Limitation

Shell Side Limitation

34
 Tube Side Limitation

 Heat transfer coefficient greatly limited in laminar flow

 Susceptible to film boiling and mist flow conditions
 Limited shear stress at the wall to combat fouling

Augmentation Devices

35
 Augmentation Devices: Shell Side

LPD LOK baffles Twisted Tubes

Multi-tubes with peripheral baffles Longitudinal finned tubes

Augmentation Devices: Shell Side

LOK-BAFFLE™ Low Pressure Drop Baffle

 Pure longitudinal flow (for LOK-BAFFLE™)

 Grids supporting the tubes even on triangular pitch
 Much lower shell side pressure drop with respect to
segmental baffles

36
 Augmentation Devices: Shell Side
Longitudinal Fintubes

 Fins provide extended surface, support the tube

element in the shell

Augmentation Devices: Shell Side

 Longitudinal Fintubes for Multi-tubes with Peripheral

Baffle

37
Augmentation Devices: Tube Side
Tube Inserts
• Twisted Tape

• HELICORE™

• Wire Wrapped Core

Augmentation Devices: Tube Side

Wire Wrapped Core

Twisted tape HELICORETM

38
Augmentation Devices: Tube Side

Hairpin Case Study

39
 Hairpin Case Study

Typical applications

 Feed / effluent
 Compressor coolers
 Lean / rich systems (TEG and Amine)
 Offshore gas coolers
 Flow line heaters
 Fuel gas heaters

Hairpin Case Study

1) Export Gas Compressor

2) Discharge Cooler
3) Gas / Gas Exchanger
4) Gas / Liquid Exchanger
5) Fuel Gas Superheater

40
 Weight Footprint Cost

HP S&T HP S&T HP S&T

Export Gas Comp. Disc. Cooler 0,27 1 0,55 1 0,69 1

Biggest hairpins ever built

(North Sea)

41
 Weight Footprint Cost

HP S&T HP S&T HP S&T

Gas / Gas Exchanger 0,4 1 0,9 1 0,83 1

Weight Footprint Cost

HP S&T HP S&T HP S&T

0,34 1 0,47 1 0,83 1

42
 Weight Footprint Cost

HP S&T HP S&T HP S&T

0,34 1 0,34 1 0,84 1

Fuels Gas Preheaters

43
 Benefits of Hairpin Technology
Weight (lb) Footprint (sq ft) Cost

HP S&T HP S&T HP S&T

Export Gas Comp. Disc. Cooler 63,000 234,000 266 486 $249,450 $360,000

Gas / Gas Exchanger 55,800 138,000 288 315 $174,000 $210,000

Gas / Liquid Exchanger 21,000 61,000 84 177 $87,500 $105,000

Fuel Gas Superheater 40,300 120,000 113 330 $159,000 $190,000

180,100 553,000 751 1,308 $669,950 $865,000

SAVINGS 372,900 557 $195,050

Hairpin Inspection & Maintenance

44
 Inspection
INSPECTION OF UNIT
At regular intervals and as frequently as experience indicates, an
examination should be made of the interior and exterior condition of all tubes.
Neglect in keeping all tubes clean may result in complete stoppage of flow
through some tubes, which could cause severe thermal strains and/or
leaking tube joints.
Exchangers subject to fouling or scaling should be cleaned periodically. A
light sludge or scale coating on the tube greatly reduces its efficiency. A
marked increase in pressure drop and/or reduction in performance usually
indicates that cleaning is necessary.
Cleaning can be done using conventional hydro-jet cleaning or cleaning in
place.

Maintenance: Parts
It is recommended that when a heat exchanger is dismantled for any cause,
it is reassembled with new gaskets.
This will tend to prevent further leaks and/or damage to the gasket seating
surfaces of the heat exchanger. Composition gaskets become dried out and
brittle so that they do not always provide an effective seal when reused.
Metal, or metal-jacketed gaskets, when compressed initially, flow to match
their contact surfaces. In so doing they are work hardened and, if reused,
may provide an imperfect seal or result in deformation and damage to the
gasket contact surfaces of the exchanger.

SPARE AND REPLACEMENT PARTS

For procurement of spare or replacement parts please refer to spare parts
list and detail drawing, which have been previously furnished, or to the parts
list drawing.

45
 Typical Hairpin Unit

Bonnet Shell Closure

Assembly Assembly Assembly

Bonnet Assembly

Bonnet Gasket

Replace

46
 Shell Assembly
Shell Nozzle Gasket

Shell Nozzle Gasket

Replace

Closure: Separated Head

Seal/Sealing Ring Split Ring Tube Gasket

T-gasket
Reusable
Replace

47
 Closure: TAPER-LOK™

Seal/Sealing Ring Split Ring Taper Ring/Gasket

T-gasket
Reusable
Replace

Closure: Lok-Flange

Seal/Sealing Ring Seal/Sealing Ring

T-gasket T-gasket
Reusable
Split Ring
Replace

48
 Upgrading

TWISTED TUBE® Bundle Technology

More than 1800
applications to date

49
 What is TWISTED TUBE®
Technology?
 Special shaped tubes for extra swirl flow: Increases
turbulence and achieves superior heat transfer.
 Cleanable triangular tube pitch for more tube quantity.
 No Baffles: Tubes are self supporting and eliminate
need for baffles. Reduces pressure drop.
 Use of shroud to control by-pass and flow direction.

TWISTED TUBE® Bundle Technology

Comparison
Baffle-free design means lower pressure drop & no dead spots

Uniform flow distribution, no dead spots.

Uneven flow distribution. Low flow & dead spots.

Fouling build up

50
 TWISTED TUBE® Bundle Technology
Design: Custom Fit

This tube provides a similar effect as the turbulator however, no insert is

used since the tube is formed in a shape that promotes swirl flow of the
tubeside fluid.

TWISTED TUBE® Bundle Technology

Design: Swirl Flow for Turbulence

51
TWISTED TUBE® Bundle Technology
Design: Eliminate Vibration

• Tubes are firmly supported.

• Vibration Free : Vcr > 305 m/s (1000 ft/sec)

– No single tube can vibrate.

TWISTED TUBE® Bundle Technology

Design: Shroud to Control Flow

52
 TWISTED TUBE® Bundle Technology
Design: Shroud- Convert “E” to “F”

TWISTED TUBE® Bundle Technology

Design: Shroud- Replacement “F” Bundle

53
 TWISTED TUBE® Bundle Technology
Increase Surface Area

Example
# 1278 tubes, 19.05 mm (¾”) OD
on 25.4 mm (1”) rotated square pitch

vs.

# 1850 tubes, 19.05 mm (¾”) OD

on 22.5 mm (8/9”) triangular pitch

+45%

Thermo-Hydraulic Design Software

KHT DLL

= TEMA type designs (conventional tubes)

& TWISTED TUBE® Exchanger

54
 Thermo-Hydraulic Design Software

KHT DLL
(Koch Heat Transfer Dynamic Link Library)

• Developed by KHT, based on experimental data collected at

different sites/laboratories.
• FREE to subscribe. Internet download (link & password).
• Instead of a "standalone", integrated with HTRISM
• Continuous improvement through R&D.

Applications

55
 Common Refinery & Petrochemical Applications
 Feed / Effluent exchangers (horizontal or vertical):
 Hydro-treaters, Reformers, Hydro-crackers
 Crude Pre-heat
 Overhead Condensers
 Reboilers (Kettle and Thermo-syphons)
 Any Service where Capacity Increased is required:
 Increased flowrate.
 Increased Surface Area.
 Closer temperature approach.
 To eliminate vibration problems.
 To reduce pressure drop.
Currently in excess of 1,000 installations in over 30 country around the
world

TWISTED TUBE® Bundle Upgrade

Higher Thermal Effectiveness Improves Heat Recovery
• The higher the energy recovered from the hot stream the lower
the quantity of fuel to burn in the heater to bring the feed (or
the crude) to the desired temperature.
• Applicable to: Crude Distillation Units (CDU), Hydrocrackers,
Hydrotreaters, Reformers.

Fuel cost
savings &
Thermal reduced CO2
Efficiency emissions

56
 TWISTED TUBE® Bundle Upgrade
Higher Hydraulic Efficiency Reduces Pressure Drop
• Lower pressure drop across the exchanger = Lower electric
energy consumption for the pump or the compressor.
• Opportunities for process optimization or for increasing flow
rate.

Fuel cost
savings &
Hydraulic reduced CO2
Efficiency emissions

TWISTED TUBE® Bundle Upgrade

Potential to Reduce Fouling
• Improved fluid-dynamic conditions, both in the tubes and in the
bundle, reduce the amount of fouling.
• Thermal and hydraulic performances do not suffer degradation
for longer time.

Fluid
Dynamic Fouling
Efficiency

57
 TWISTED TUBE® Exchanger Texas Tower Combined
Feed/Effluent Exchanger

Reduced
Size and
Thermal Quantities of
Efficiency Exchangers

Frequently Asked Questions

 What about cleaning?
 Shellside & tubeside conventional hydroblasting
 Cleaning in place

 What about inspection?

 IRIS, Acoustic Eye, Guided Wave, Eddy current

 What about the cost?

 No direct equivalent to conventional exchangers.
 More tubes, More material, More work done.
 Higher performance, Longer operation time, Lower maintenance.
 Evaluation should be based on total installed cost,
maintenance cost savings, energy savings and
efficiency/performance gains

58
 Summary of Advantages
 Performance and cleanability of a conventional square tube
combined with area density of a triangular layout on a tighter pitch.
 Capacity Increase.
 Flow-Induced Vibrations are Completely Eliminated.

 Compared to conventional S & T HEx, typically heat transfer

coefficients are ~40% higher for the same pressure drop, OR
pressure drop is halved for the same heat transfer coefficient.
 Lower energy costs.
 Smaller Footprint for Same Duty.
 Lower maintenance costs.
 Lower installation costs.

Upgrading

59
 Objective Of The Heating System

 Reduce product viscosity to allow contents to be

pumped from the tank.
 Asphalt, fuel oils, lube oils, crude oils, etc.

 Freeze protection- Water, sulfur, etc.

 Heat product to account for heat losses during

transportation.

Fundamental Heat Transfer Equation

Q= U0 . A0 . ∆Tm

Increase Area (A0) = Increases duty (Q)

Increased surface area allows duty to be maintained whilst

reducing temperature difference (∆Tm)

60
 Fundamental Heat Transfer Equation
Q= U0 . A0 . ∆Tm

Fundamental Heat Transfer Equation

Q= U0 . A0 . ∆Tm
For Tank Heating:
Q is the duty or sum of the heat losses from the tank to the
atmosphere and the duty required to heat up the tank contents (if
applicable).
Tm (also written as MTD) is the mean temperature difference,
which depends upon the heating medium temperature and desired
tank temperature.
Ao is the heater surface area
Uo is the overall heat transfer coefficient

61
 Tank Heating Equipment

Line Serpentine

Manway
Suction

Vertical

Serpentine Manway

Tank Heater Design Considerations:

 Heat loss on tank (Top, Sides, Bottom) and Thermal

Insulation
 Direct vs. Indirect systems.
 Cost vs. type of energy used
 (eletricity vs. steam vs. hot oil).
 Risks associated with each type of energy
 (leaks, fire, supply failure).
 Maintenance and inspection of the different systems
 (material, cleaning frequency, repair cost, labor).

62
 Storage Tank Heating With Coils

 Heating of viscous fluids with coils is one of the most

efficient alternatives in large size tanks.
 Many tanks use bare tubes or pipe....

BROWN FINTUBE® Tank Heaters with

Longitudinally Finned Tubing
Finned Tube
Bare Tube

By adding longitudinal fins to the tube we are able to

increase the heat transfer surface area substantially when
compared to bare tubing.

63
 BROWN FINTUBE® Tank Heaters with
Longitudinally Finned Tubing
Finned Tube
Bare Tube

 For Same Footprint: Can Increase Duty

 For Same Duty; Can reduce heating medium temperature
• Lower energy costs and emissions
 Provides Smaller footprint
• Keep more product in tank.
 Lower “skin temperature” reduces product degradation, coking
and corrosion.
 Piping does not cover entire tank floor
• Lower maintenance costs

Reducing Metal Temperature to Minimize Coking

and Product Degradation

64
 BROWN FINTUBE® Tank Heaters
Comparison
Bare Tubing

 Heating viscous fluids with coils is one of the most common methods
for large size tanks.
 Many tanks use bare tubes or pipe....

BROWN FINTUBE® Tank Heaters

Comparison
Finned Tubing

 Finned tubing provides up to 12 x surface area of bare pipe.

65
 BROWN FINTUBE® Tank Heaters
Comparison
Finned Tubing:
Vertical Type

 Finned tubing provides up to 12 x surface area of bare pipe.

Bare Pipe vs. Finned Pipe:

Example 1: In Tank
Conditions:

 Maintain tank containing Fuel Oil @ 100°F

 Heating Medium = 14.7 PSIA saturated steam @ 212°F
 Duty = 4,000,000 BTU/Hr. & MTD = 112°F

Options:

 2” Bare Pipe option (0.622 sq. ft./ft.)

 2” Finned Pipe Option w/ (40) ¾” high perforated fins / tube

66
 Bare Pipe vs. Finned Pipe:
Example 1: In Tank

Bare Pipe Option Finned Pipe Option

UO= 28 UO= 16
A REQD= 1276 Sq.Ft. A REQD = 2,260 Sq.Ft.
= 2050 linear ft. of pipe = 453 linear ft. of finned pipe

Suction Heater

 Mounting: Directly to the side of the Tank.

 Heats only what you use.
 Reduces pumping viscosity.
 Typically less expensive than heating an entire tank.
 ASME code.
 Bundle removable from outside the tank.

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 Options to Reduce Energy Costs
Suction and Line Heaters

 If a minimum temperature is kept inside the tank which allows

the viscous fluid to flow, the final temperature required to
reduce pumping viscosity (energy consumption) can be
reached with a suction heater.
 An inline heater can be used with the same purpose with the
additional advantage that it can be used to heat the fluids of
more than one tank.

Bare Pipe vs. Finned Pipe:

Example 2: Suction / Line
Conditions:

 Product pumping temperature is 275°F

 Tank: 150 Ft diameter x 50 Ft high
 Ambient design temp is 10F
 2” Fiberglass insulation
 Heating medium is 150 psig steam
 Required surface area: 2000 square ft.
Options:

 2” Bare Pipe option (0.622 sq. ft./ft.)

 2” Finned Pipe Option w/ (40) ¾” high perforated fins / tube

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 Bare Pipe vs. Finned Pipe:
Example 2: Suction / Line

Bare Pipe Option Finned Suction and Line Heater

Requires 3200 linear feet of 2” pipe.
Heat losses will be 1,430,000 Btu/hr.
Steam requirement is 1,665 #/hr.
Estimated energy costs are $43,800/yr.
based on $3.00/1000# steam
 Requires (4) tank heater and (1)
suction heater.
 Heat losses will be 970,000 Btu/hr.
 Steam requirement is 1,130 #/hr.
 Estimated energy costs are $29,800/yr.
 based on $3.00/1000# steam

BROWN FINTUBE® Vertical Tank Heaters

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BROWN FINTUBE® Vertical Tank Heaters

• Vertical heaters induce strong thermal currents such that

product adjacent to the fintube rises rapidly creating a thermal
siphon effect.
• Sedimentation is minimized, as particles are kept in
suspension.

Summary of Advantages

 Lower energy costs

 Reduced Heating Medium Temperature
 Smaller Footprint- easy cleaning & inspection
 Less product displacement
 More product in tank
 Lower maintenance costs
 Lower capital and installation costs
 Fewer welds - minimize risk of leakage
 Lower metal temperature
 Reduced fouling
 Coils available from stock – quick delivery

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