Heat Exchangers

What is wear?

Wear is the gradual removal of material obtained at contacting

surfaces in relative motion. Wear implies that a material has been
rubbed against something that caused it to degrade While friction
results in important energy losses, wear is associated with increased
maintenance costs and costly machine downtime

.
Wear Plates
Introduction to Heat Exchanger

• A heat exchanger can be defined as any device that

transfers heat from one fluid to another or from or to a fluid
and the environment.
• Whereas in direct contact heat exchangers, there is no
intervening surface between fluids.
• In indirect contact heat exchangers, the customary
definition pertains to a device that is employed in the
transfer of heat between two fluids or between a surface
and a fluid.
• Heat exchangers serve a straightforward purpose:
controlling a system’s or substance’s temperature by
adding or removing thermal energy.
 What are heat exchangers for?

Heat exchangers are practical devices used to transfer

energy from one fluid to another
To get fluid streams to the right temperature for the next
process
reactions often require feeds at high temp.
To condense vapours
To evaporate liquids
To recover heat to use elsewhere
To reject low-grade heat
To drive a power cycle
HEAT TRANSFER LAW APPLIED TO HEAT
EXCHANGERS

6
Applications of Heat Exchangers
Heat Exchangers
prevent car engine
overheating and
increase efficiency
Heat exchangers are
used in Industry for
heat transfer

Heat
exchangers are
used in AC and
furnaces
 Main Categories Of Exchanger

Most heat exchangers have two streams, hot and

cold, but some have more than two
Heat Exchangers-Classifications according to Service
Heat Exchanger
Bothsides single phase and process stream
Cooler
One stream process fluid and the other cooling water
or Air
Heater
One stream process fluid and other side heating
utility as steam
Condenser
One Stream condensing vapour and the other cooling
water/air
Reboiler
One stream bottom stream from the distillation
column and the other hot utility or process stream
 Types of Heat Exchangers

Shell & Tube heat exchangers

Plate Heat exchanger

Regenerative Heat exchangers

Adiabatic Wheel heat exchangers

Fluid heat exchangers

Dynamic scraped heat exchangers

Phase change heat exchangers

APPLICATION
APPLICATION
 Plate Heat Exchanger

Plate heat exchanger 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
 Plate Heat Exchangers

Individual separated thin

corrugated parallel s.s.
plates
Gaskets separate plates
Gap approx. 1.4mm
Plate and frame arrangement
High h values at relatively low
Re values and low flow rates
can operate with small ΔT
reduced fouling easy cleaning
 Finned tubes
Radial fins
Longitudinal fins
For air/gas heaters where film
heat transfer coefficients on
gas side will be very low
compared with condensing
steam on the other side of
tube. Rate of heat transfer is
increased by increasing
surface area on side of tube
with the limiting (low) heat
transfer coefficient (gas side).
 Regenerative Heat exchanger
• The Third type of Heat exchanger is the
regenerative heat exchanger
• In this heat from process is used to
warm the fluids to be used in the
process and the same type of fluid is
used either side of the heat exchanger
• These heat exchangers can be either
plate or shell and tube construction
• Regenerator are used extensively used
in Electrical power generating units for
air preheating
• Typically uses the fluid from the different
area of the same system for both the
hot and cold fluids
 Adiabatic wheel heat exchanger
Adiabatic wheel heat exchanger is the third type that uses an intermediate
fluid or solid store to hold heat, which is then moved to the other side of
the heat exchanger to be released. For instance, adiabatic wheels
which contain large wheel with fine threads rotating through the hot and
cold fluids, and fluid heat exchangers. This kind is employed when it is
agreeable for a minimum amount of mixing to happen between the two
streams.
Adiabatic wheel heat exchanger

Adiabatic wheel heat exchangers may be created

that chemical reactions or energy generation
processes can be performed inside them. The
exchanger then becomes an integral part of the
reaction system and may be known, for instance as
a nuclear reactor, catalytic reactor or polymerizer.
Heat exchangers usually employed only for the
transfer and helpful removal or recovery of heat
without an accompanying phase change
 Fluid Heat Exchangers

This is a heat exchanger with a gas

passing upwards through a shower of
fluid (often water), and the fluid is
then taken elsewhere before being
cooled. This is commonly used for
cooling gases whilst also removing
certain impurities, thus solving two
problems at once. It is widely used in
espresso machines as an energy-
saving method of cooling super-
heated water to be used in the
extraction of espresso.
Dynamic scraped heat exchangers

Another type of heat exchanger is

called "dynamic heat exchanger" or
"scraped-surface heat exchanger".
This is mainly used for heating or
cooling with high-viscosity products,
crystallization processes,
evaporation and high-fouling
applications. Long running times are
achieved due to the continuous
scraping of the surface, thus avoiding
fouling and achieving a sustainable
heat transfer rate during the process
 Phase change heat exchangers

In addition to heating up or cooling down fluids in just

a single phase, heat exchangers can be used
either to heat a liquid to evaporate (or boil) it or
used as condensers to cool a vapour and
condense it to a liquid. In chemical plants and
refineries, reboilers used to heat incoming feed for
distillation towers are often heat exchangers
 Double pipe heat exchangers
• It consists of concentric pipes
with standard return bends.
• One fluid flows through inside
metal pipe and the second
fluid flows through the annulus
between the outside pipe and
inside pipe.
• The flow directions may be
either parallel or counter
fashions.
• These exchangers are used
when heat transfer area
required is not more than 150
sq.ft
Double pipe heat exchangers
 Shell & Tube Heat Exchanger

 Shell and Tube Heat Exchangers are one of the most

popular types of exchanger due to the flexibility the
designer has to allow for a wide range of pressures and
temperatures. There are two main categories of Shell
and Tube exchanger:
 Those that are used in the petrochemical industry
which tend to be covered by standards from TEMA,
Tubular Exchanger Manufacturers Association
 Those that are used in the power industry such as feed
water heaters and power plant condensers
 Shell & Tube Heat Exchanger
Shell and tube heat exchanger consists
of a shell with a bundle of tubes inside
it.
One fluid flows through the tubes (the
tube side) and the other fluid flows
outside the tubes but inside the shell
(the shell side).
Heat is transferred from one fluid to the
other through the tube walls, either from
tube side to shell side or vice versa.
The fluids can be either liquids or gases
on either the shell or the tube side.
 The standard nomenclature for shell and tube heat
exchanger
1. Stationary Head-Channel 20. Slip-on Backing Flange 30. Longitudinal Baffle
2. Stationary Head-Bonnet 21. Floating Head Cover-External 31. Pass Partition
3. Stationary Head Flange-Channel or 22. Floating Tube sheet Skirt 32. Vent Connection
Bonnet 23. Packing Box 33. Drain Connection
4. Channel Cover 24. Packing 34. Instrument Connection
5. Stationary Head Nozzle 25. Packing Gland 35. Support Saddle
6. Stationary Tube sheet 26. Lantern Ring 36. Lifting Lug
7. Tubes 27. Tie-rods and Spacers 37. Support Bracket
8. Shell 28. Support Plates 38. Weir
9. Shell Cover 29. Impingement Plate 39. Liquid Level Connection
10. Shell Flange-Stationary Head End 40. Floating Head Support
11. Shell Flange-Rear Head End
12. Shell Node
13. Shell Cover Flange
14. Expansion Joint
15. Floating Tube sheet
16. Floating Head Cover
17. Floating Head Cover Flange
18. Floating Head Backing Device
27
19. Split Shear Ring
 Cylinder (Shell)

Heads

Tube Sheet (Plate)

Main
Tube (Pipe) Bundle
Parts
Baffle, Tie Rod, (Pipe) Spacer

Pass Partition (Plate)

 Construction and parts:
Shell:
It is usually a cylindrical casing through which one of
the fluid flows. Shell is commonly made of carbon
steel. In special applications AS,SS, Nickel alloys are
also being used.
Tubes:
Standard heat exchanger tubes which are used in many
industrial processes may be of various sizes and
lengths.
The wall thickness of tubes is usually expressed in
terms of Birmingham Wire Gauge (BWG).
The thickness depends upon material of construction
and diameter.
Standard lengths of tubes for heat exchanger
construction are 8, 12, 16 and 20 ft.
Tube pitch:
The shortest centre-to-centre distance between the
adjacent tubes is called as tube pitch.
Tubes arranged in a triangular or square layout, known
as triangular or square pitch.
Square pitch gives lower shell side pressure drop than
triangular pitch.
Square pitch is good for easy cleaning whereas
triangular pitch gives more number tubes for same
space available
Unless shell side fluid fouls badly, triangular pitch is
used.
TEMA standards specify a minimum center to
center distance 1.25 times outside diameter of the
tubes for triangular pitch and a minimum cleaning
lane of ¼ inch for square pitch.
Tube layouts

pitch
Triangular Rotated Rotated
Square square
30o triangular
90o 45o
60o

Typically, 1 in tubes on a 1.25 in pitch or 0.75 in

tubes on a 1 in pitch
Triangular layouts give more tubes in a given shell
Square layouts give cleaning lanes with close pitch
Tube sheet:
It is essentially a flat circular plate. A large number of
holes are drilled in the tube sheet according to the
pitch requirements.
Baffles:
The baffles are installed in the shell
1) To increase the rate of heat transfer
by increasing the velocity and
turbulence of the shell side fluid
2) It helps as structural supports for
tubes and dampers against vibration.
3) The baffles cause the fluid to flow
through shell at right angles to the
axes of the tubes (Cross flow).
OR
They promote cross flow
Tube bundle- Plate Baffle Types
Types of Baffles
 Baffles-Arrangement

To avoid the bypassing of the shell side fluid the

clearance between the baffles and shell, and baffles
and tubes must be minimum.
The centre-to-centre distance between adjacent baffles
is known as baffle spacing or baffle pitch.
The baffle space should not be greater than the inside
diameter of the shell and should not less than the one-
fifth if the inside diameter of the shell.
The optimum baffle spacing is 0.3 to 0.50 times the
shell diameter
 Tube Bundle

Construction

Bundle of tubes in large cylindrical shell

Baffles used both to support the tubes and to direct
into multiple cross flow
 Heat Exchanger standards

The design and construction is usually based on TEMA 9th

Edition 2007
Supplements pressure vessel codes like ASME and BS
5500
Many users have their own additions to the standard which
suppliers must follow
ISO standard for heat exchanger(Shell & Tube) is ISO
16812:2019
API standard for heat exchanger(Shell & Tube) is API
660:2015
TEMA Code Overview

TEMA Classes

Class R- Generally severe requirements for

Petroleum and related Processing applications
Class C- Generally moderate requirements of
commercial and general processing applications
Class B- Chemical processing applications
 TEMA terminology

Rear end
Front end head type
Shell
stationary head type

Letters given for the front end, shell and rear end types
Exchanger given three letter designation
Above is AEL
TEMA’s Standard Shell, Front-end and Rear-end Types
Single pass 1-1 exchanger:
Multipass Heat Exchangers
MULTI PASS HEAT EXCHANGERS:
 Multi pass construction decreases the cross section of the
fluid path and increases the fluid velocity and corresponding
HT Coefficient
Advantages:
1) High velocities
2) Short tubes
3) Solution to expansion problems

Disadvantages:
1) Exchanger is more complicated
2) Friction loss are increased because of high velocities,
longer path ,multiplication of entrance and exit
losses
 Connection of Tube and Tube Sheet
i. Expansion Joint
 Tube to Tube sheet joint

Expansion Weld
API 660
The tube to tube sheet joint shall be expanded only, unless otherwise
specified or approved by purchaser. If welded joints are specified the joints
shall be made by one of the following methods

A) Strength welded only

B) Strength welded and expanded
C) Seal welded and expanded
Tube Bundle-Inspection Stages
1) Drawing Review:
Surveyor has to review the drawing thoroughly
including notes and reference made in the drawing,
to understand all requirements.
2) Material Identification report for pressure parts:
This is the report submitted by the manufacturer and it
is as per ASME Boiler and Pressure Vessel Code
Section II. It is the responsibility of the Surveyor to
check that the materials of construction are in line
with code, standard and project specific requirements
.
Tube Bundle-Inspection Stages
3) WPS,PQR & WPQ review
Surveyor has to verify the qualified welding procedures
and qualified welders are being used by the
manufacturer.
4) NDE
Review and or examination of the results of any
specified non destructive examination
1.Radiography
2.MPI
3.LPI
4.Hardness test- on weld, HAZ
All NDE should be done after PWHT.
Tube Bundle-Inspection Stages

5) Dimensional Inspection:
Drawings review and material identification report are the
steps prior to the start of fabrication. After both these
steps, the fabrication processes start and inspection is
done after completion of every machining process listed
below.
i) Tube sheet machining
ii) Tube sheet drilling
iii) Tube sheet grooving
iv) Baffle plates cutting and drilling
v) Tubes cutting
vi) Tie rods cutting and machining
Tube sheet- After Final machining
 MOCKUP TEST –TUBE EXPANSION

Dimensions listed below shall be recorded for each tube and tube
holes.
a. Tube holes ID
b. Tubes ID
c. Tubes OD

The completed test pieces shall be examined as follow:

a. Visual examination
b. Dye Penetrant examination
c. Microscopic examination for the test piece A
d. Pull Test (Weld Strength Test) for test piece B
Tube to Tube sheet joint Test Fixture-ASME SEC.VIII Appendix. A
Mockup test- Tube expansion -Hydro test
Tube to Tube sheet Joints-ASME Sec.VIII Appendix A
Tube Bundle-Inspection Stages

4) Bundle Assembly:
Inspection is done after tubes are inserted in baffle
plates and both sides’ tube sheets and tie rods
are affixed. At this stage; the total length of tube
bundle, from one tube sheet to other; distance
between baffles are measured and have to be as
per drawing. This stage is important as after this
stage, tubes are expanded and any rectification
thereafter is difficult.
TUBE BUNDLE-BAFFLE ASSLY
Tube Bundle- Tube Expansion

At this stage, inspection is done to determine if all

the tubes are properly expanded
 3.Connection of
Tube and Tube Sheet
i. Expansion Joint

Before Expansion After Expansion

Tubes shall be expanded into the tube sheet for a length no
less than 2" (50.8 mm) or the tube sheet thickness minus
118" (3.2 mm), whichever is smaller. In no case shall the
expanded portion extend beyond the shell side face of the
tubes heet.
Tube Bundle-Inspection Stages

Tube Expansion:
At this stage, inspection is done to determine if all
the tubes are properly expanded.
We normally use 7% expansion in CS tubes and 3-
5% in SS tubes, for LAS 4%.
Code does not specify the amount of expansion.
Expansion shall not be exercised beyond the tube
sheet face
.
Tube Bundle- Tube expansion in the tube sheet

% expansion is calculated as;

% Expansion= {(D-d)-c}/2t

D= inside diameter of tube after expansion.

d= inside diameter of tube before expansion.
t= nominal wall thickness of the tube.
c = clearance between tube outside diameter and tube hole
diameter in the tubesheet

.
Tube Bundle-Inspection Stages

Final Dimensional Inspection:

Prior to installation of tube bundle into the shell, a final
dimensional inspection is done.
The bundle dimension shall be checked based on the
approved drawing.
The baffle diameter and distance between them shall be
controlled and meet the acceptance tolerances in the
drawing.
The tightness of stay bolts and spacers must be controlled.
The shell cleanliness needs to be verified and make sure the
inside welds are complete and are ground as per drawing
requirements.
Shell- Inspection Stages

For Shell and Channel shells the inspection stages are same as
pressure vessel inspection Stages
Heat Exchanger-assembly Dimensions
Assembly dimensions, nozzles orientation, position,
projection
Name plate details & position, saddle supports location,
orientation & dimensions(diagonal variation between
mounting holes),Earthling cleat location and completeness
are to be verified as approved drawing and project section
requirement
Documents verification
All inspection documents as per ITP/Project specific
requirements to be verified for the completeness and
correctness before hydro test
Heat Exchanger assembly- Leak Testing of Seal Weld (Tube to Tube sheet)

If seal welding considered, then the leak test will be

a mandatory requirement. The shell side will be
subjected to the air pressure, and water and soap
solution will be sprayed to the tube sheet to make
sure all seal welds are defect free. The bubble will
be developed if there was any welding defect such
as crack, pinhole, etc.
 Heat Exchanger assembly- Shell side Hydrostatic Testing
After manufacturing completion, the heat exchange shell
Shell side Hydrostatic Testing - After manufacturing completion, the heat exchange shell side will be subjected to the hydrostatic testing. The test pressure
side will be subjected to the hydrostatic testing. The test
amount shall be consistent with the value indicated in the approved drawing. The holding time shall be based on the supplier approved test procedure.
The pressure gages calibration and range shall be controlled. The pressure gage range shall be within 1.5 thru 4 times of test pressure. The shell body and welding
seams shall be inspected. The tubesheet also shall be checked. No leakage is allowed.

pressure amount shall be consistent with the value

indicated in the approved drawing. The holding time shall
be based on the supplier approved test procedure.
The pressure gages calibration and range shall be
controlled. The pressure gage range shall be within 1.5
thru 4 times of test pressure. The shell body and welding
seams shall be inspected. The tube sheet and inside the
tubes also shall be checked. No leakage is allowed
 Heat Exchanger assembly- Tube side Hydrostatic Testing

After successful completion of shell side hydrostatic

testing, the bonnets are assembled, and tube side is
subjected to hydrostatic testing. Similarly, the amount of
test pressure shall be as the one indicated in the
approved drawing. Other requirement is similar to the
shell test. No leakage and pressure drop shall be
observed while the tube side is under pressure.
 Painting & Final inspection
1.Shell and tube cleaning & drying to be verified.
2.Purging requirement to be verified –if applicable
3.Painting inspection to be done as per ITP scope
4. Painting inspection report to be verified for the surface
preparation and painting scheme as per Project specific
requirements.
5.Completness and name plate verification
6.Packing inspection if applicable
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