BVF2244 HEAT EXCHANGER OPERATIONS, MAINTENANCE & TROUBLESHOOTING

CHAPTER 1 : INTRODUCTION OF HEAT

EXCHANGER

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Ts. Dr. Noor Sabrina binti Ahmad Mutamim
COURSE OUTCOME
Understand the working concept of the heat exchanger.

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HEAT TRANSFER

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The general function of a heat exchanger is to transfer heat from one fluid to
another. The basic component of a heat exchanger can be viewed as a tube/wall
with one fluid running through it and another fluid flowing by on the outside. There
are thus three heat transfer operations that need to be described:

1. Convective heat transfer from fluid to the inner wall of the tube or plate,
2. Conductive heat transfer through the tube wall or plate
3. Convective heat transfer from the outer tube wall/plate wall to the outside fluid.

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Transfer of Thermal Energy between:
1. Two or more fluids

2. Between a solid surface and a fluid

3. Between solid particulates and a fluid

Classification of Heat Exchangers

Types of HE
1. Double-pipe exchanger
2. Shell and tube exchangers
3. Plate and frame exchangers
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled heat exchangers
7. Agitated vessels.
8. Fired heaters.
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Based on Transfer Process
1. Indirect Contact – Shell & Tube Heat
Exchangers
2. Direct Contact – Cooling Towers
Based on Phase of Fluids
1. Gas-Liquid exchangers
2. Liquid-Liquid exchangers
3. Gas-Gas heat exchangers
Based on Construction
1. Tubular
• Double pipe heat exchanger
• Shell and tube heat exchangers
• Spiral heat exchangers
2. Plate-type
• Plate and frame heat exchangers
• Spiral plate heat exchangers
3. Extended Surface
• Plate-fin exchanger
• Tube-fin exchanger
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Based on Flow Arrangements

Parallel flow / Co-current flow

Counter flow

Cross flow

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Heat Transfer Coefficient
Heat transfer rate, 𝑞 = 𝑈𝐴∆𝑇𝑚

q = heat transfer rate, W = J/s

U = overall heat transfer coefficient, W/(m2oC) ,
A = heat transfer surface area, m2
∆𝑇𝑚 = mean temperature difference, oC

Overall Heat Transfer Coefficient, Uo

ho= outside fluid film coefficient, W/(m2.oC)

hi= inside fluid film coefficient, W/(m2.oC)
hod= outside dirt coefficient (fouling factor), W/(m2.oC)
hid= inside dirt coefficient, W/(m2.oC)
kw= thermal conductivity of the tube wall material, W/(m2.oC)
di= tube inside diameter, m
do= tube outside diameter, m
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Temperature Profile: Co-current flow

Log Mean Temperature

Difference (LMTD)

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Temperature Correction Factor (Ft )

1. Mean temperature difference, ∆𝑇𝑚

∆𝑇𝑚 𝐹𝑡∆𝑇𝑙𝑚

2. Ft depends on R & S

𝑇ℎ𝑖 𝑇ℎ𝑜
𝑅
𝑇𝑐𝑜 𝑇𝑐𝑖

𝑇𝑐𝑜 𝑇𝑐𝑖
𝑆
𝑇ℎ𝑖 𝑇𝑐𝑖

Temperature correction factor: one shell

pass; two or more even tube passes

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SHELL & TUBE HEAT
EXCHANGERS

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Components of a STHE
1. Shell
2. Shell cover
3. Tubes
4. Channel
5. Channel Cover
6. Tubesheet
7. Baffles
8. Floating-Head Cover
9. Nozzles
10.Tie-Rods & Spacers
11.Pass Partition Plates
12.Impingement Plates
13.Sealing Strips & Sealing Rods

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Classification by Construction
Fixed-tubesheet Heat Exchanger
1. Has straight tubes secured at both ends to tubesheets welded to the shell

2. Low cost, simplest construction.

3. Bundle is "fixed" to the shell so outside of the tubes cannot be cleaned mechanically.

4. Application is limited to clean services on the shell side

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U-tube Heat Exchanger

1. Tubes are bent in the shape of a U

2. Only one tubesheet
3. Bending of tubes adds to the cost
4. Tube bundle is removable, outside of tubes can be cleaned.

5. Because of the U-bend, inside of the tubes can’t be cleaned

mechanically
6. Can’t be used for dirty fluids inside tubes.

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Floating Head Exchanger
1. Most versatile and costliest.

2. One tubesheet is fixed relative to the shell, and the other is free to “float” within the shell.

3. Cleaning of both the insides and outsides of the tubes

4. Can be used for services where both the shell-side and the tube-side fluids are dirty

Widely used in Petroleum Industry

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Straight-Tube ( 1-Pass )

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Straight-Tube ( 2-Pass )

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 TEMA Types
Tubular Exchanger Manufacturer Association

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TEMA Types

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Fluid Allocation

Shell Side Tube Side

1. Viscous Fluids 1. Fluids which are prone to fouling
2. Lower Flow Rates 2. Corrosive fluids
3. Cleaner Fluids 3. Toxic fluids to increase containment
4. High pressure streams, since tubes are less expensive
to build strong
5. Streams with low allowable pressure drop
6. Cooling water to be put on tube side only

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Tubes
Tubes should be able to withstand:
1. Operating temperature and pressure on both sides

2. Thermal stresses due to the differential thermal expansion between the shell and the tube

bundle
3. Corrosive nature of both the shell-side and the tube-side fluids

TUBE PITCH RATIO:

Min 1.25 times of tube OD

1.333 times of tube OD
1.5 times of tube OD
TUBE PASS: Based on pressure drop & velocity limit on tube side

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Tube Layout Angle

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 Feature Tube Layout Pattern

Lower ΔP on shell-side Square (effective only at low Re number)

Shell-side fouling Square - easier cleaning

Horizontal shell-side Boiling Square

Fit 15% more tubes if triangular pitch

Smaller shell size
used

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Tube Pitch
1. Shortest distance between two adjacent tubes

2. TEMA specifies a minimum tube pitch of 1.25*(OD)

3. Minimum tube pitch leads to smallest shell diameter for a given number of tubes.

4. To reduce shell-side pressure drop, the tube pitch may be increased to a higher value.

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Tubesheet
1. Barrier between shell-side and tube-side fluids.
2. Mostly circular with uniform pattern of drilled holes.
3. Tubes are attached to tubesheet

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Tie Rods and Spacers
Tie rods and spacers are used for:
1. holding the baffle assembly together
2. maintaining the selected baffle spacing

Sliding Strips
1. help the bundle to slide out from the shell

2. Can also be used as tie rods to hold the bundle in position.

Sealing strips and Seal rods

1. Sealing strips prevent shell side fluid from bypassing the bundle.

2. Sealing strips block the resulting large open area at top or bottom of the shell.

3. Seal rods are also used to control the leakage streams.

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Tube Pass Layout

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Types of Baffles
 Segmental type;

1. Single – horizontal & vertical

2. Double

3. Triple

4. No-Tubes in Window (NTIW)

 Orifice type

 Disc and doughnut type

 Rod type

 Impingement type

 Longitudinal (pass partitions)

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 ORIENTATION:
1. Horizontal for heating or cooling with no phase
change
2. Vertical for shell side condensation

 CUT:
1. 15 % to 45 % of shell ID for Single Segmental
2. 25 % to 35 % of shell ID for Double Segmental

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Baffle Cut
1. Height of the segment that is cut in a baffle to permit the shell- side fluid to flow
across the baffle.
2. Baffle cut should be set carefully because a baffle cut that is either too large or
too small can increase the possibility of fouling in the shell, and moreover it
would also lead in inefficient shell-side heat transfer
• CUT:
1. 15 % to 45 % of shell ID for Single Segmental
2. 25 % to 35 % of shell ID for Double Segmental

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Baffle/ Nozzle Orientation
 The orientation of the baffle cut is important for heat exchanger installed
horizontally.
1. When the shell side heat transfer is sensible heating or cooling with no phase change,
the baffle cut should be horizontal.
2. For shell side condensation, the baffle cut for segmental baffles is vertical.
3. For shell side boiling, the baffle cut may be either vertical or
horizontal depending on the service.
 Positioning of inlet/ outlet nozzle is also important for the proper functioning of exchangers.
1. In cooling water services, the inlet nozzle should be at the bottom and outlet nozzle
should be at the top.
2. For condensing services exit should be from the bottom nozzle.

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Single Segmental Baffle - Horizontal

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Single Segmental Baffle - Vertical

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Double Segmental Transverse Baffle

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Doughnut and Disc Types Baffles

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Baffle Spacing
1. Baffle spacing is the longitudinal or centreline-to- centreline distance between adjacent baffles.

2. According to TEMA, the minimum baffle spacing should be one-fifth of the shell inside diameter

or 2 in., whichever is greater.

3. The maximum baffle spacing is the shell inside diameter.

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Impingement Devices
• Impingement rod, Impingement plate, Nozzle Impingement baffle are the various devices

used in heat exchangers to trim down the effects of high velocity at entry nozzles over
tube bundle.

Tube Problems
1. Scaling of inside/outside of the tube surface

2. Blockage of tube passage

3. By passing across the baffle

4. Puncture in the tube

5. Leakage through the tube to tubesheet

6. Leakage through gasketted joint of floating head

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Bypass & Leakage streams: TINKER FLOW MODEL
• B stream: Main heat transfer stream, follows a path around baffles and through tube bundle

• A stream: Leakage stream, flowing through clearance between tubes and holes in baffles

• C stream: Tube bundle bypass stream in the gap between the tube bundle and shell wall

• E stream: Leakage stream between baffle edge and shell wall

• F stream: Bypass stream in flow channel partitions due to omissions of tubes in tube pass

partitions.

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FLOW FRACTIONS ALLOWABLE LIMITS
A Stream < 10 %
B Stream > 40 %
C Stream < 10 %
E Stream < 15 %
F Stream < 10 %

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Bypass & Leakage Streams
Since the flow fractions depend strongly upon the path
resistances, varying any of the following construction
parameters will affect stream analysis and thereby the shell side
performance of an exchanger:
1. Baffle spacing and baffle cut
2. Tube layout angle and tube pitch
3. Clearance between the tube and the baffle hole
4. Clearance between the shell I.D. and the baffle
5. Location & no. of sealing strips and sealing rods

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Temperature Cross (Co-current)

• Outlet temperature of cold stream cannot

be greater than the outlet temperature of

the hot stream.
• An F shell has 2 shell passes, so if there

are 2 tube passes as well, it represents a

pure counter-current flow

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Air Cooled Heat Exchanger

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Plate and Frame Heat Exchanger

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Spiral Heat Exchanger

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THANK YOU

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