HEAT EXCHANGERS
TRAINING FOR PROFESSIONAL PERFORMANCE
This manual is one of a series for your use
in learning more about equipment that you
work with in the petroleum industry. Its pur-
pose is to assist in developing your knowl-
edge and skills to the point that you can
perform your work in a more professional
manner.
The manual was prepared so that you can
learn its contents on your own time, without
the assistance of an instructor or classroom
discussion. Educators refer to learning by
self-study as Programmed Learning. It is a
method widely used in all industries as a
means of training employees to do their job
properly and teach them how to perform higher
rated jobs.
You can demonstrate your desire to be a
professional by taking a positive attitude to-
ward learning the contents of this manual and
others that are applicable to your job.
The author of this manual has years of
experience in operating petroleum equipment.
He also has the technical knowledge of how
and why petroleum equipment functions.
The text was written for use by personnel with
little or no previous experience with petro-
leum equipment. Consequently, some of the
material may be familiar to you if you have
experience with oilfield equipment. From such
experience, you have observed the effect of
making operating changes. The manual will
help explain why the changes occurred that
you observed. It will also teach you how and
why equipment functions.
© 2003 Petroleum Learning Programs Ltd. No part of this manual may be reproduced in any form. Its use as a
reference in training courses is specifically reserved for Petroleum Learning Programs Ltd. All translation rights are
likewise reserved.
HEAT EXCHANGERS
In order for you to learn the contents of the
manual, you must dig out the pertinent facts
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the material and answering the questions is
not enough. The more effort you make to
learn the material, the more you will learn from
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Teaching yourself requires self-discipline
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Once you have established your final goal,
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als to get the basic knowledge and skills you
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completing each section of the material.
Achieving your final goal may take more
than a year, and will require hours of hard
work on your part. You will know you have
achieved your goal when you understand
how and why to operate oilfield equipment in
order to obtain the maximum product at the
lowest cost. Your sacrifice will have been
worth-while from the satisfaction of knowing
that you can perform your job in a methodical
professional manner, instead of a trial-and-
error approach.
 INSTRUCTIONS FOR USING THIS MANUAL
This your manual. You should write your
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find it helpful to keep it in an accessible place
for future reference.
Problems are included throughout the text.
The solutions to the problems are given at the
end of the book.
The manual is used in training programs
all over the world. In some countries, English
units of measurement such as feet, gallons,
pounds, etc, are used. In other countries,
Systems Internationale (SI) or Metric units,
such as meters, liters, kilograms, etc., are
used. In order for the manual to be of maxi-
mum use, both SI and English units are shown.
The SI unit always appears first, and the
English unit follows in brackets [ ]. Example:
the temperature is 25°C [77°F]. The English
equivalent of the SI unit will be rounded off to
the nearest whole number to simplify the text
and examples. A distance of 10 m may be
shown as 33 ft whereas the exact equivalent
is 32.81 ft.
If you are working in English units, you
may find it helpful to mark out the parts that
are in SI units and vice versa.
Some of the Figures have units of meas-
urement. In such cases, two figures are in-
cluded. The first one is in SI units, and the
second-figure will be on the next page and will
have English units. Each figure is identified
with SI or English units. Be sure you use the
figures in the units you are working in.
The following procedure is recommended
for using this manual:
1. Turn to Page 1. Read the material until
you come to the first problem or ques-
tion.
2. Work the first problem or answer the
question and enter the answer in the
proper space in ink. If the problem or
question is shown in both SI and En-
glish Units of measurement, answer
only the part in units of measurement
that you use.
3. Compare your answer with that shown
at the end of the book; be sure to use
solutions to the problems in the units
you are working in.
If your answer is correct, continue read-
ing until you come to the next problem
and work it. If not, restudy the manual
until you understand the reason for
your error. Rework the problem if
necesary. Leave your wrong answer
and note the correct one. This will keep
you from making the same mistake
later on.
4. Proceed stepwise as shown above
until you have completed the text.
The above approach will require thought,
making mistakes, and rethinking the situ-
ation. Concenrate on two things — the how
and why. Do not cheat yourself by taking
short-cuts or looking up the answers in ad-
vance. It saves time and errors but produces
no real understanding. Your future depends
on how efficiently you perform your job and
not on how rapidly you proceed through this
manual. Since this is your manual, any errors
you make are private.
A validation or test covering the entire
manual is included at the back of the book.
Answers will be sent to your supervisor or
training director at their request at no cost.
HEAT EXCHANGERS
 ABBREVIATIONS USED UNITS OF MEASUREMENT
IN THIS MANUAL
SI UNITS OF MEASUREMENT
SI UNIT ABBREVIATIONS
Most of the SI units of measurement used in the
oilfield are traditional metric units. The exceptions we
s, min second, minute, time
are concerned with are pressure and heat units. The
h, d hours, day time
SI pressure unit is kilopascal; the heat units are joule
mm millimeter length and watt. A watt equals 1 joule per second. Coversions
cm centimeter length from traditional metric units to SI units are as follows:
m meter length
m2 square meter area METRIC SI
CONVERSION
m3 cubic meter volume UNIT UNIT
m3/d cubic meters per day volume rate Pressure bar kilopascal, kPa kPa = bar x 100
l liter volume joule, J or J = cal x 4.2
Heat calorie
g, kg gram, kilogram weight watt, W W = J ÷ time, sec.
Pa, kPa pascal, kilopascal pressure
kPa(a) kilopascal absolute pressure
MPa megapascal pressure
bar bar (1 bar = 100 kPa) pressure
STANDARD CONDITIONS
J, kJ joule, kilojoule heat, work FOR GAS
MJ megajoule (J x 106) heat, work
W,kW watt, kilowatt power Measurement units for gas volume are cubic meters
per day (m3) or thousands of cubic feet per day (Mcf/
ENGLISH UNIT ABBREVIATIONS d). The letters st or s are sometimes used with the
units to designate volume at standard temperature
s, min second, minute time and pressure: m3d (st) or Mscf/d. In this manual,
h, d hour, day time standard volumes are corrected to a temperature of
in, ft inch, foot length 15°C and a pressure of 101.325 kPa(a), or 60°F and
sq in square inch area 14.7 psia.
sq ft square foot area
cu ft cubic foot volume To simplify the text, the letters st and s are omitted.
gal gallon volume However, all gas volumes shown are at standard
bbl barrel (42 US gal) volume conditions unless specifically stated otherwise.
BPD barrels per day volume rate
lb pound weight
psi lbs per square inch pressure
psia lbs per sq in absolute pressure HEAT CAPACITY AND
Btu British thermal unit heat RELATIVE DENSITY
MBtu thousand Btu heat
MMBtu million Btu heat
Specific heat and specific gravity are traditional
W, kW watt, kilowatt electric power terms that have been used in both Metric and English
hp horsepower mechanical power units for many years. These names are being re-
cf/d cubic feet per day gas flow rate placed with the terms: heat capacity and relative
Mcf/d thousand cf/d gas flow rate density. The new names are used in this manual.
MMcf/d million cf/d gas flow rate When you see the term heat capacity (Ht Cap), it will
M thousand have the same meaning as specific heat, and relative
MM million density (Rel Dens) means specific gravity.

HEAT EXCHANGERS
 HEAT EXCHANGERS
TABLE OF CONTENTS

INTRODUCTION ...................................................................................................................... 1
I. TYPES OF EXCHANGERS ............................................................................................ 2
A. Shell and Tube .......................................................................................................... 2
B. Hairpin Exchangers ................................................................................................... 8
C. Plate Type Exchangers ........................................................................................... 10
D. Plate-Fin Exchangers .............................................................................................. 10
E. Aerial Coolers .......................................................................................................... 11
F. Miscellaneous Type of Exchangers......................................................................... 14
II. PRINCIPLES OF HEAT TRANSFER ........................................................................... 16
A. General.................................................................................................................... 16
B. Temperature Difference .......................................................................................... 16
1. Temperature Approach ...................................................................................... 20
C. Heat Exchanger Coefficient..................................................................................... 21
D. Heat Exchanger Area .............................................................................................. 22
E. Heat Exchanger Duty .............................................................................................. 23
F. Pressure Drop ......................................................................................................... 25
G. Actual Heat Transfer ............................................................................................... 25
1. Conversion of Liquid Volume to Weight ............................................................. 27
2. Conversion of Gas Volume to Weight ................................................................ 28
3. Heat of Vaporization or Condensation ............................................................... 29
III. APPLICATION OF EXCHANGERS .............................................................................. 33
A. Shell and Tube ........................................................................................................ 33
B. Hairpin ..................................................................................................................... 33
C. Aerial Cooler............................................................................................................ 34
D. Plate Type Exchanger ............................................................................................. 35
E. Plate-Fin .................................................................................................................. 35
IV. OPERATION OF EXCHANGERS ................................................................................ 37
A. Shell and Tube, Hairpin Plate Type, and Plate-Fin ................................................. 37
B. Aerial Coolers .......................................................................................................... 38
V. TROUBLESHOOTING EXCHANGER PROBLEMS ..................................................... 39
A. Shell and Tube and Plate Type ............................................................................... 39
B. Aerial Coolers .......................................................................................................... 42
C. Locked Sidestream Heaters .................................................................................... 44
VI. LOW TEMPERATURE EXCHANGER PROBLEMS ..................................................... 46
A. Inlet Gas-to-Outlet Gas Exchangers ....................................................................... 46
B. Gas Chiller............................................................................................................... 46
EXCHANGER COEFFICIENTS ....................................................................................... 49, 50
EXTERNAL AREA OF EXCHANGER TUBES ....................................................................... 51
VALIDATION - SI UNITS ....................................................................................................... 53
SOLUTIONS TO PROBLEMS - SI UNITS ............................................................................. 54
VALIDATION - ENGLISH UNITS ........................................................................................... 55
SOLUTIONS TO PROBLEMS - ENGLISH UNITS ................................................................. 56

HEAT EXCHANGERS
 LIST OF DRAWINGS AND ILLUSTRATIONS

Shell and Tube Exchangers ......................................................................... 1, 3, 4, 5, 7, 33, 40

Hairpin Exchangers ............................................................................................................ 9, 34
Plate Type Exchangers .................................................................................................... 10, 36
Plate Fin Exchangers ....................................................................................................... 10, 35
Aerial Coolers ....................................................................................................... 12, 13, 14, 34
Miscellaneous Exchangers .................................................................................................... 15
Heat Transfer ......................................................................................................................... 16
Example of Determining Minimum in Number of Tubes ......................................................... 18
Example of Fluid Temperature Difference ............................................................................. 19
Example of Temperature Approach ....................................................................................... 20
Flow of Heat ........................................................................................................................... 21
Example of Area Calculation .................................................................................................. 22
Example of Exchanger Duty ............................................................................................. 23, 24
Pressure Drop Measurement ................................................................................................. 25
Examples of Actual Heat Transfer ............................................................................. 26, 27, 28
Example of Calculation of Liquid Weight from Volume .......................................................... 27
Example of Heat Transfer in Liquid ........................................................................................ 27
Example of Calculation of Gas Weight from Volume ............................................................. 28
Example of Heat Transfer in Gas ........................................................................................... 30
Example of Heat of Vaporization ............................................................................................ 30
Example of Theoretical vs. Actual Duty ................................................................................. 31
Exchanger Start-Up ................................................................................................................ 37
Locked Side Stream heater ............................................................................................... 44,45
Gas Chiller ............................................................................................................................. 47
Lube Oil in Chiller ................................................................................................................... 48

HEAT EXCHANGERS
 HEAT EXCHANGERS
INTRODUCTION
Heat exchangers are used to conserve
heat and save fuel, or to supply heat required
by a process.
The simplest heat exchanger is a kitchen
pan used to boil water. Heat is transferred
from the heating element on the stove to the
water in the pan. An ice tray in a refrigerator is
another simple heat exchanger.
A heat exchanger can be thought of as any
piece of equipment in which heat is trans-
ferred from a warm substance to a cool mate-
rial through a wall that separates the two
SHELL AND TUBE HEAT EXCHANGERS
1
substances.
A heat exchanger is an energy transfer
device. Energy, in the form of heat, transfers
from the warm fluid to the cool one. The
amount of energy that transfers is often far
more than the size of the exchanger indicates.
For example, more of the energy released
from gasoline ignition in an automobile engine
passes out the radiator (a heat exchanger)
than is converted to mechanical energy to
drive the vehicle.
HEAT EXCHANGERS
2 I. TYPES OF EXCHANGERS
A. Shell and Tube Exchangers
The most common types of heat exchang-
ers used in process plants are shell and tube
exchangers. Drawings of such equipment are
shown in Figures 1, 2, 3 & 4.
Shell and tube exchangers have two obvi-
ous major components:
1. A tube bundle, which may contain hun-
dreds of tubes and through which the tube
side fluid flows.
2. A shell that encases the tube bundle and
through which the shell side fluid flows.
For our purposes, a fluid is a liquid or gas
or a mixture of the two.
The tube material is usually steel, bronze
or aluminum, although stainless steel or other
alloys can be used in corrosive or severe
temperature services. A tube sheet supports
and seals the tubes. Each tube is inserted in
a hole in the tube sheet and a special tool is
inserted inside the end of the tube which
uniformly expands the tube to fit the hole in the
tube sheet. The shell is almost always steel.
The inside of a tube usually can be cleaned
fairly easily by pushing a rod through it, or
using a high pressure jet on the end of the rod.
The outside surface of tubes in an exchanger
tube bundle is more difficult to clean, as the
surface of many of the tubes is inaccessible.
Consequently, the fluid that is the most likely
to corrode or form scale usually flows inside
the tubes. If special material, such as stain-
less steel, is required to prevent corrosion,
only the tubes and heads have to be made of
the special material. If the corrosive fluid were
to flow in the shell side, the tubes and shell
would have to be made of a brass alloy called
Admiralty, and water flows through the tubes.
HEAT EXCHANGERS
If both fluids have similar corrosive proper-
ties, the highest pressure fluid usually flows
through the tube side. This is because a tube
will collapse from an external pressure about
one-half the internal pressure that is required
to burst the tube. For example, a steel tube
that will burst when its internal pressure
reaches 18 600 kPa [2700 psi] will collapse
when the pressure outside the tube reaches
8300 kPa [1200 psi]. It is less expensive to
make an exchanger with the higher pressure
on the shell side.
The two major factors that influence the
selection of the tube side fluid are pressure
and fouling. If one of the fluids is water, it will
almost always flow in the tubes, even though
it is usually the lowest pressure fluid. Select-
ing the hot or cold fluid, or gas or liquid to flow
in the tubes is not a factor. In other words, the
amount of heat transfer is not significantly
effected with the hot fluid inside or outside the
tubes; or with gas or liquid inside or outside.
As we will see later, the amount of heat
transfer that occurs in an exchanger depends
upon the area of metal that separates the two
fluids. In a shell and tube exchanger, the heat
transfer area is the external area of the tubes.
The reason that shell and tube exchangers
are commonly used is that they are usually the
least expensive means of providing the area
required for heat transfer to occur.
Most shell and tube exchangers are
mounted in a horizontal position. If either fluid
is a liquid, it usually enters at the bottom of the
exchanger — either shell or tube side — and
flows out the top. With this flow pattern, the
exchanger will stay full of liquid and the entire
tube area will be utilized. If liquid flows in the
top and out the bottom, vapor pockets can
TYPES OF SHELL AND TUBE EXCHANGERS 3

Figure 1
TYPES OF SHELL AND TUBE EXCHANGERS

HEAT EXCHANGERS
4 HEAT EXCHANGER PARTS

form, and no heat transfer will take place in the Shell and tube exchangers have three
tubes that are within the vapor pocket. common flow configurations:
Exchangers can be mounted vertically 1. Single pass
with no change in their efficiency, but preven- 2. Two pass
tion of vapor pockets is just as important as in 3. Multipass
horizontal mountings.
HEAT EXCHANGER PARTS
1. Stationary Head–Channel 20. Slip-on Backing Flange
2. Stationary Head–Bonnet 21. Floating Head Cover–External
3. Stationary Head Flange–Channel or Bonnet 22. Floating Tubesheet Skirt
4. Channel Cover 23. Packing Box Flange
5. Stationary Head Nozzle 24. Packing
6. Stationary Tubesheet 25. Packing Follower Ring
7. Tubes 26. Lantern Ring
8. Shell 27. Tie Rods and Spacers
9. Shell Cover 28. Transverse Baffles or Support Plates
10. Shell Flange–Stationary Head End 29. Impingement Baffle
11. Shell Flange–Rear Head End 30. Longitudinal Baffle
12. Shell Nozzle 31. Pass Partition
13. Shell Cover Flange 32. Vent Connection
14. Expansion Joint 33. Drain Connection
15. Floating Tubesheet 34. Instrument Connection
16. Floating Head Cover 35. Support Saddle
17. Floating Head Flange 36. Lifting Lug
18. Floating Head Backing Device 37. Support Bracket
19. Split Shear Ring 38. Weir
39. Liquid Level Connection

Figure 2
HEAT EXCHANGER PARTS

HEAT EXCHANGERS
TYPES OF SHELL AND TUBE EXCHANGERS 5

SINGLE-PASS SHELL AND TUBE,

FIXED TUBE SHEET
WITH EXPANSION JOINT ON SHELL SIDE

SINGLE PASS SHELL AND

2-PASS TUBE
WITH REMOVABLE TUBE BUNDLE

2-PASS SHELL AND TUBE

WITH REMOVABLE TUBE BUNDLE

Figure 3
TYPES OF SHELL AND TUBE EXCHANGERS

HEAT EXCHANGERS
6 SHELL AND TUBE EXCHANGERS

A fluid makes one pass when it flows from 2. To assure turbulent flow of the shell fluid
one end of the exchanger to the other. The top for maximum heat transfer.
exchanger on Figure 3, is an example of a
Another feature of shell and tube exchang-
single pass tube and single pass shell. Each
ers is that they can be made so that the tube
fluid enters one end and leaves at the other.
bundle can be removed. All of the exchangers
A common arrangement is the middle
shown in Figures 2, 3 and 4 except the top unit
exchanger in Figure 3, which has two passes
in Figure 3 have removable tube bundles.
on the tube side, and a single pass on the shell
Replacing a fouled bundle can usually be
side.
done in a fraction of the time required to clean
An exchanger can have any number of
it in place. In addition, the tube bundle can be
passes. Each pass must be sealed from the
replaced, if necessary, for less than the cost
others so that the fluid does not by-pass the
of a new exchanger.
exchanger. Refer to the exchanger in Figure
Where corrosion or fouling is not likely to
2; the tube side fluid enters at the bottom on
occur in the exchanger, there is no reason to
the left and flows to the right in the lower half
have a removable tube bundle. A nonremov-
of tubes. When it reaches the end, it turns
able or fixed tube sheet type of unit can be
180° and flows to the left in the upper half of
used, which is less costly than the removable
tubes. The partition plate, Part no. 31, seals
bundle. The top exchanger in Figure 3 is an
the lower inlet chamber on the tube side from
example of a fixed tube sheet exchanger.
the upper outlet chamber. If the seal plate
Care must be taken in designing a fixed tube
leaks, some inlet fluid will flow directly to the
sheet exchanger to allow for the difference in
outlet end, and it would receive no heat ex-
expansion or contraction of the shell and
change.
tubes so that the tubes don’t pull out of the
The shell side of an exchanger is more
tube sheet or buckle from compression.
difficult to seal, and consequently more than
For example, suppose hot oil at 315°C
two passes are seldom used. The longitudinal
[600°F] is used on the shell side to heat a
baffle or seal plate, item 30, shown on the
stream of naphtha at 38°C [ 100°F ] in a single
lower drawing in Figure 3, has a packing
pass fixed tube sheet exchanger. The aver-
groove along the entire length of the baffle
age temperature of the tubes will be around
that is filled with packing to seal the top half of
177° [350°F]. The shell or outer wall of the unit
the shell from the lower half. If the seal leaks,
will be about 232°C [450°F]. At 232°C [450°F]
some shell side fluid can flow in one nozzle
temperature, the shell may ‘grow’ in length by
and out the other without ever flowing the
10 mm [!/2 in.] from expansion due to heat,
length of the exchanger. In this exchanger,
whereas the tubes elongate only 5 mm [!/4 in.]
both shell and tube fluids make two passes.
from heat. As the shell expands, it may make
The shell side of shell and tube exchang-
the tubes stretch until they pull out of the tube
ers has transverse baffles, Items 28 on Fig-
sheet or break in two.
ures 2 and 3, that serve two functions:
This situation can be taken care of by
installing an expansion joint on the shell side
1. To keep the tubes from sagging or touch- (Top Exchanger of Figure 3.) If the pressure
ing each other. on the shell side is more than an expansion

HEAT EXCHANGERS
 REBOILERS 7

KETTLE REBOILER

THERMOSIPHON REBOILER

Figure 4
TYPES OF SHELL AND TUBE REBOILERS

HEAT EXCHANGERS
8 HAIRPIN EXCHANGERS
joint can take (usually about 1700 kPa [ 250
psi ] maximum), a floating head or U-tube
bundle will probably be necessary to allow the
tubes to expand or contract independently of
the shell. Figures 2, 3 and 4 indicate types of
construction which allow tube movement in-
dependent of the shell.
The upper illustration in Figure 4 is a type
of shell and tube exchanger commonly called
a reboiler. It is actually a combination ex-
changer and gas-liquid separator. In this par-
ticular drawing, a heating fluid such as steam
or hot oil flows through the tubes. The shell
side fluid is a liquid which partially vaporizes.
It enters the bottom of the shell in the nozzle
at the left. As the fluid flows to the right, some
of it vaporizes and passes out the top nozzle
in the center of the vessel.
The liquid that remains flows over the weir,
which is to the right of the tube bundle so that
liquid will always cover the tubes in order that
the full tube area is available for heat transfer.
The illustration referred to is commonly
called a kettle type reboiler. It is used to
provide the heat required in a stripper or
fractionation tower. Its design must provide
for enough free space above the level of liquid
over the tube bundle for vapors to separate
from boiling liquid in the shell.
The lower exchanger shown in Figure 4 is
called a thermosiphon reboiler. The heating
fluid makes a single pass through the tube
side. Liquid from a fractionation tower or strip-
per enters the two bottom nozzles on the shell
side. Some of the liquid vaporizes in the shell
side. The combined shell side stream, which
is liquid and vapor, passes out the top and
flows back to the tower from which it came.
The selection of a kettle or thermosiphon
type of reboiler is made by the designer of the
tower to which the reboiler supplies heat.
There are no hard and fast rules for selection
of one over the other.
The kettle type of reboiler also is used in
refrigeration plants to chill a stream of gas or
absorption oil. In this application, the refriger-
ant (usually propane) flows in the shell side,
HEAT EXCHANGERS
and the gas or absorption oil flows through the
tubes. The refrigerant is a cold liquid when it
enters the exchanger. As it cools the tube side
stream, it absorbs heat and is vaporized. The
vapors leave the top of the unit and flow to a
compressor. (See Manual P-10, REFRIG-
ERATION)
Each shell and tube exchanger used in a
process plant is designed for the specific
service in which it is used. The tube diameter,
length, and number of tubes are selected for
one application. Their design and construc-
tion must be in accordance with rigid specifi-
cations by a heat exchanger association. Since
each exchanger is tailor-made for one job,
there is little chance that it could be effectively
used in another application.
B. Hairpin Exchangers
An illustration of a hairpin or U-tube type of
exchanger is shown in Figure 5. In most
applications, it has two passes on both shell
and tube sides. The tube bundle can have
several tubes, or a single tube made of pipe.
A single tube often has longitudinal fins on the
outside to increase the heat transfer area.
The tube bundle can be removed through
the back end. A sealing device is located on
the front end, which is easily disassembled to
allow removal of the tubes. The shell of the
exchanger is made of standard pipe.
Makers of hairpin exchangers build them
to standard sizes, using standard materials
for the shell and tubes. When these exchang-
ers are used, the supplier determines which of
the standard units, or a combination of stan-
dard units, will provide the required heat trans-
fer duty. The units are not tailor-made to each
application as shell and tube units are.
The units are supplied with mounting brack-
ets that enable them to be stacked atop one
another, or mounted side-by-side. Several
units may be required in a given service. They
may be used in series or in parallel.
One of the features of the hairpin exchang-
ers is that additional sections can be added to
an existing installation at a reasonable cost.
 HAIRPIN EXCHANGERS 9

SINGLE TUBE WITH FINS

DETAIL OF BEND DETAIL OF

FRONT TUBE SEAL

MULTI-TUBE WITH FINS

DETAIL OF BEND
DETAIL OF
FRONT TUBE
SEAL

Figure 5
HAIRPIN EXCHANGERS

HEAT EXCHANGERS
10 PLATE FIN EXCHANGERS

C. Plate Type Exchangers cleaned fairly easy.

Plate type exchangers have a series of
plates in which the hot fluid flows between
every other plate, and the cool fluid flows
between the other plates. Each fluid makes
one pass. These units are built with standard
sized plates. Plates can be made of steel,
aluminum, bronze, or other special metals to
withstand corrosion.
The distance between plates is the thick-
ness of the sealing gasket, so they are seldom
used when a fluid contains solid material of
any size.
D. Plate Fin Exchangers
Plate fin exchangers are usually made of
aluminum and used in low temperature ser-
vice as an alternative to using stainless steel
to withstand cryogenic temperatures. They
can be constructed to withstand operating
pressures over 8 500 kPa [1200 psi].
The exchangers resemble an auto radia-
tor encased in an aluminum shell. The close
tolerances between the plates and fins result
in the units serving as filters to remove any
solid particles that may be present in either
process fluid. Some operators have had suc-
cess in removing solid particles by back-flow-
ing in surges with nitrogen.

The number of plates

varies with the heat trans-
fer requirement. Each plate
is sealed from the adjoin-
ing one with a gasket. Thus,
an exchanger requiring 100
plates will have 100 seal-
ing gaskets. Because of
the possibility of gasket
leakage, this type of ex-
changer is seldom used at
pressures above 2000 kPa
[ 300 psi ].
One of the advantages
of plate type exchangers is
that plates can be easily
added or removed as pro-
cess flow rates change. An-
other advantage is that the
plates can be removed and

HEAT EXCHANGERS
 AERIAL COOLERS
E. Aerial Coolers
Aerial coolers are simply exchanger tubes
exposed to a stream of air moving across
them. The tubes usually have aluminum fins
pressed onto the outer wall of the tubes to
increase the heat transfer area. Air is blown
across the tubes with a fan driven with an
electric motor or engine. The exchangers are
frequently called fin-fan units.
Drawings of typical aerial coolers are
shown in Figure 6.
The tube fluid usually makes at least 2
passes, and frequently has 6 or 8 passes. Air
flow is single pass.
Each end of the exchanger has a header
in which the tubes are rolled or welded. Figure
7 shows a typical header. A plug is located in
the header opposite each tube to give access
to the tubes for cleanout, to replace, or to plug
it if it is leaking.
Aerial coolers have 5 basic components:
1. Tubes
2. Headers
3. Fan and driver
4. Plenum chamber
5. Support structure
Components are shown in Figure 6. The
fan can be mounted below the tubes and blow
air up, which is a forced draft arrangement;
or it can be mounted above the tubes and pull
air across the tubes, which is an induced
draft arrangement. The induced draft type is
more expensive than the other. However, it is
often preferred because it is more efficient
since it offers less chance for hot exhaust air
being sucked back and recycled through the
tubes.
The fans usually have 4 to 8 propeller type
11
blades. The blades are made of aluminum or
plastic. The blades can be supplied with a
variable pitch to change the rate of air flow.
Variable pitch blowers are used selectively
because of their cost and maintenance. The
speed of the fan can also be varied to control
air flow.
The tubes and headers in an aerial ex-
changer are usually made of standard grades
of steel. Special alloys can be used in corro-
sive services. The structural portion is also
made of steel. It can be galvanized for corro-
sion protection.
Vibration switches are frequently mounted
on aerial coolers to shut down the fan driver
when excessive vibration occurs. Excessive
vibration is usually caused when one or more
of the fan blades gets out of balance with the
others. This can be caused by:
1. Accumulation of dirt or scale on
blades.
2. A blade twists in its housing, so that its
pitch is different from the others.
3. A blade cracks or breaks apart, or some
material flies off of the tip of the blade.
4. Worn bearings on the fan shaft.
If corrective action is not taken immedi-
ately when a blade gets out of balance, exces-
sive vibration can cause the unit to fly apart
and damage or injure nearby equipment or
personnel.
Most aerial coolers used in process plants
are tailor made for the specific application in
which they are used. Standard size units can
be used for engine radiators, air conditioning
condensers, and other similar services where
the heat transfer duty is relatively constant.
One of the most commonly used aerial
exchanger is that of a radiator on an automo-
bile. It is an induced draft type of aerial cooler.
HEAT EXCHANGERS
12 AERIAL COOLERS

It varies from a conventional cooler in that a
core is used instead of tubes. Since it oper-
ates at a low pressure, and a leak would not
be hazardous, a rugged construction is not
required. The plates making up the core are
stamped to shape and soldered together in an
assembly-line type of construction that re-
quires very little manual labor.
During cold weather operation of aerial
coolers, it is often necessary to restrict the
flow of air across the tubes to prevent too
much cooling of the process fluid in the tubes.
A common method for restricting the air flow is
to use louvers in the air stream.

HEAT EXCHANGERS
AERIAL COOLERS 13

HEAT EXCHANGERS
14 AERIAL COOLERS
They are installed above the tubes on
forced draft units, and below the tubes on
induced draft types. The louvers can be posi-
tioned by hand, or can be moved with an
automatic controller.
In extremely cold weather locations, lou-
vers may not provide enough restriction of air
to prevent the fluid in the tubes from freezing.
A recirculating air system is provided for such
applications. In this type of unit, air circulates
through the blower, across the tubes, and
back to the blower. Each time the air passes
across the tubes, its temperature rises. The
air temperature is controlled by admitting some
cold air from outside the exchanger housing
and discharging an equal volume of circulat-
ing air to the atmosphere.
RECIRCULATING AERIAL COOLER
FOR LOW AMBIENT TEMPERATURE LOCATIONS
HEAT EXCHANGERS
F. Miscellaneous Types of Exchangers
Quite frequently, the presence of an ex-
changer in process equipment is not obvious.
Pressure vessels, such as Separators or Con-
tactor towers, often have heating coils near
the bottom of the vessel through which a hot
fluid circulates to prevent liquid in the vessel
from freezing. The coil is an exchanger tube
and the vessel is the shell.
Pipe or tubing coils are frequently used in
process equipment for heat transfer. The length
and size of the coil is determined in the same
manner as the design of a sophisticated shell
and tube exchanger.
Another commonly used exchanger that is
not obvious is that of a pipe-in-pipe arrange-
ment, where the fluid flowing inside the smaller
pipe is used to heat or cool the fluid in the
outer pipe.
 MISCELLANEOUS HEAT EXCHANGERS 15

Steam boilers and gas fired heaters are also forms of heat exchangers. They are not included
in this manual because they require design and operating procedures that are not applicable to
conventional heat exchangers.

Problem 1

Match items in the right column with the appropriate item in the left column.
____ A. Shell & tube Exchanger 1. Flows inside tubes
___ B. Hairpin Exchanger 2. Used in low temperature service
___ C. Plate Type Exchanger 3. Designed for 1 specific application
___ D. Plate Fin Exchanger 4. Shell fluid is air
___ E. Aerial Cooler 5. Maximum operating pressure is
2000 kPa [300 psi]
___ F. Corrosive fluid 6. Shell and tube fluids make 2 passes

HEAT EXCHANGERS
16 II. PRINCIPLES OF HEAT TRANSFER
A. General
The process that takes place in a heat
exchanger is that of heat transfer. For the
sake of uniformity, we always consider heat
movement from the warm fluid to the cool
fluid. In an aerial cooler, heat from the fluid in
the tubes transfers to air blowing across the
tubes. In a gas Chiller, heat in the warm gas
is transferred to the cold refrigerant. Heat is a
form of energy. Thus, a heat exchanger is an
energy transfer device.
It is important that you visualize the move-
ment of heat from the warm fluid to the cold
one in order to understand the principles of
heat transfer. You can think of heat transfer in
an exchanger as though a part of the warm
fluid moved through the tube and mixed with
the cool fluid. The amount of heat that leaves
the warm fluid is obviously the same as the
amount that enters the cool fluid.
Remember: Heat transfer is the movement of
heat from the warm fluid to the cool fluid.
Another term you need to remember is
that of duty. The duty of an exchanger is the
amount of heat that transfers in an hour. The
duty is usually expressed in watts or Btu/hr.
The watt is the SI unit for heat energy. A
watt equals one joule per second. A joule is
the amount of heat required to raise the tem-
perature of 0.24 grams of water by 1°C.
A British thermal unit (Btu) is the En-
glish unit of heat energy. It is the amount of
heat required to raise the temperature of 1 lb
Heat
Warm Fluid Cool Fluid
HEAT TRANSFER
Heat flows from warm fluid to cool one.
HEAT EXCHANGERS
of water by l°F.
The amount of heat that transfers in an
exchanger will be the quantity that leaves the
hot fluid. Obviously, this same quantity will
enter the cool fluid.
Thus, the duty of an exchanger will be
either the quantity of heat that leaves the hot
fluid in an hour—watts [ Btu/hr ]—or the quan-
tity that enters the cool fluid in an hour.
The duty of a heat exchanger is deter-
mined from three factors:
1. Temperature difference between the two
fluids.
2. Coefficient of the exchanger, which de-
pends on the type of exchanger and the
properties of the two fluids.
3. Surface area of tubes or plates.
The equation for determining the heat trans-
fer that will occur in an exchanger is:
Duty = (∆T)(Coeff)(Area)
Where:
∆T = average temperature difference of
the fluids, °C [°F]
Coeff = Coefficient from pages 49 & 50
Area = External area of tubes or plates
B. Temperature Difference
One of the fluids in an exchanger is the hot
one, and the other is the cold one. The tem-
perature difference between the fluids is the
force that drives or pushes the heat from the
hot fluid to the cold one. If both fluids are at the
same temperature, the temperature differ-
ence is obviously 0°, and no heat will transfer.
The amount of heat that transfers in an ex-
changer varies directly with the temperature
difference between the hot and cold fluid.
 FLUID TEMPERATURE DIFFERENCE 17

A greater temperature difference will re-
sult in more heat transfer; or to put it another
way, a smaller (and less expensive) exchanger
can be used with a higher temperature differ-
ence. Thus, exchangers are designed for
maximum temperature difference between
the two fluids.
Suppose we have an insulated tank with 2
compartments as shown below. Hot water is
in the left compartment, and cool oil is in the
other. It would appear that the temperature
difference in the two liquids is 93 - 38 = 55°C
[200 - 100 = 100°F]. The heat exchanger in
this situation is the wall separating the two
liquids. The water temperature at the com-
partment wall will quickly cool to about 70°C
[160°]; and the oil temperature next to the wall
will rise to about 60°C [140°F]. Thus, the
temperature difference at the exchanger is
only 70 - 60 = 10°C [160 - 140 = 20°F],
although it is 5 times this amount a short
distance away from the exchanger.

∆T ∆T
Heat Heat

TEMPERATURE DIFFERENCE BETWEEN FLUIDS, ∆T, IS FORCE THAT

DRIVES HEAT FROM WARM FLUID TO COOL FLUID

93°C 93°C
[200°F] [200°F]

Oil Water Oil

Water

38°C [100°F] 38°C [100°F]

STATIC CONDITION TURBULENT CONDITION

Temperature Difference at Temperature Difference at

compartment wall is about compartment wall is 55°C
10°C [20°F] [100°F].

HEAT EXCHANGERS
18 FLUID TEMPERATURE DIFFERENCE
If we put agitators in each compartment to
violently stir each side so that the temperature
of each liquid will be the same throughout its
compartment, we will have the maximum tem-
perature difference at the exchanger. Heat
transfer will be at its maximum rate.
Now suppose that the oil and water that
were in the 2 compartments are flowing
through the shell and tube sides of an ex-
changer. The cold oil is outside the tubes, and
hot water is inside. If both fluids are flowing at
a low velocity, flow will be laminar, which will
correspond with the static compartment tem-
peratures. The temperature of water in the
middle of the tube will be higher than the
temperature only a short distance away at the
tube wall. On the shell side, the oil tempera-
ture next to the tube will be higher than that a
short distance away.
If we increase the velocity of the fluids so
that flow is turbulent, the temperatures will be
Example
Water flowing at a rate of 4 200 l/min [1100 gpm] passes through the tube side of an exchanger.
The tubes will have turbulent flow if the water rate through each tube is at least 8.4 l/m [ 2.2 gpm
]. How many tubes will be required?
Sl UNITS
Total water flow 4 200 l/min
Flow per tube for 8.4 l/m
turbulent flow
Maximum Number of 4 200
= 500
tubes 8.4
The maximum number of tubes at a flow of 4 200 l/m [1100 gpm] is 500 in order to
maintain turbulent flow.
HEAT EXCHANGERS
those of the compartments with agitators.
Exchangers are designed so that flow will
be turbulent. You recall in the discussion on
shell and tube exchangers that baffles are
used on the shell side to direct the flow of fluid.
If there were no baffles, the shell side fluid
would move slowly though the exchanger.
The baffles cause the fluid to move up and
down as it flows through the exchanger,
thereby increasing the velocity. Enough baffles
are included on the shell side to assure turbu-
lent flow.
Turbulent flow of fluid in the tubes is main-
tained by limiting the number of tubes or
plates in an exchanger.
Occasionally, the design is such that flow
is not turbulent in the tubes. In such cases,
turbulence is induced by inserting a metal
strip in the tube that has been twisted in the
shape of a spiral.
ENGLISH UNITS
1 100 gpm
2.2 gpm
1 100
= 500
2.2
 FLUID TEMPERATURE DIFFERENCE 19

The temperature difference of the two fluids ture difference involves the use of logarithms
is the average of the difference of the fluid and is not necessary for you to know the proce-
temperatures entering and leaving the ex- dure. The important thing for you to remember is
changer. It is determined by calculating the that the average temperature difference is some-
difference in temperature of the fluids at the inlet what less than the arithmetic average. For our
end and the outlet end; and adding the two purposes, the arithmetic average will be accu-
together and dividing by two. rate enough.
Calculation of the exact average tempera-
Example
Determine the average temperature difference in the oil cooler shown below.

6 + 3339
Average ∆T = = = 19.5°C
2 2
10 + 60 70
[Average ∆T = = = 35°F]
Example 2 2
An aerial cooler is used to cool gas from a compressor. Temperatures are as shown
below. Calculate the average temperature difference.

A simplified drawing of the exchanger looks like this:

121 °C 49 °C
GAS
∆t = 121 - 60 = 61°C [ 250°F] V [ 120°F] ∆t = 49 - 32 = 17°C
[ ∆t = 250 - 140 = 110°F] 60°C W 32°C [ ∆t = 120 - 90 = 30°F]
AIR
[ 140°F] [ 90°F]
SI UNITS ENGLISH UNITS
Average ∆T = 61+17 = 78 = 39°C 110 + 30 = 140 = 70°F
2 2 2 2

HEAT EXCHANGERS
20 TEMPERATURE APPROACH
1. Temperature Approach
One of the most useful tools for use in
troubleshooting an exchanger problem is that
of the temperature approach. The tempera-
ture approach is the temperature difference
between the hot and cold fluids on the end of
the exchanger that the main process fluid
leaves. The temperature approach can be
illustrated with an oil cooler.
The main process fluid in the above ex-
changer is obviously oil. It exits on the left end,
so that is the end to measure the temperature
approach. It is 6°C [10°F]. We have ap-
proached within 6°C [10°F] of cooling the oil to
the lowest temperature possible with 32°C
[90°F] water.
In the above exchanger, water is heated
as it removes heat from the oil. However, the
main funtion of the exchanger is to cool oil and
not heat water.
Suppose the outlet oil temperture from the
above exchanger rose to 44°C [110°F]. It
appears that there is a problem in the ex-
changer. Before doing anything else, check
Type of Exchanger
Shell and Tube
Hairpin
Plate or Plate-fin
Aerial
HEAT EXCHANGERS
the temperature approach. If the cooling wa-
ter inlet temperature has risen 6°C [10°F], the
temperature approach will be the same, and
no exchanger problem exists. The problem is
due to a high water temperature.
If the water temperature has not risen, the
temperature approach will be higher, which is
almost a certain indication of an exchanger
problem — plugging, fouling, etc.
Thus, when you have an apparent ex-
changer problem, check the temperature ap-
proach first. If it has not changed, the problem
is rarely a fouled exchanger; it is almost al-
ways a process problem — changes in flow
rates and/or temperatures of the process
streams.
On the other hand, if the temperature
approach rises, an exchanger problem almost
certainly exists.
If you are not sure which end the main
process fluid leaves, determine the tempera-
ture difference on each end, and the lowest
one is the temperature approach.
Typical temperature approaches for vari-
ous type of exchangers are shown below:
Temperature Approach
SI Units Engligh Units
5.5° - 11°C 10° - 20°F
8° - 16°C 15° - 30°F
3.3° - 8°C 6° - 15°F
8° - 16°C 15° - 30°F
 HEAT EXCHANGER COEFFICIENT
In order to determine whether or not the
temperature approach has changed, a per-
manent record of the approaches for each
Problem 2
The average temperature difference in the following gas-to-gas exchanger is ________°.
The temperature approach is ________°.
C. Heat Exchanger Coefficient
In an exchanger, heat must travel through
the hot fluid to the wall of the exchanger, then
move through the wall or tube, and enter the
cool fluid.
The speed at which heat moves from the
hot fluid to the cool fluid will depend upon the
properties of the fluids. The rate of heat travel
in water is fairly fast; it is lower in liquid
21
exchanger should be prepared when exchang-
ers are in good operating condition.
hydrocarbons, and much lower in gases.
The coefficient of an exchanger is a measure
of the amount of heat that will transfer in one
hour across 1 square meter [ 1 sq ft] of
exchanger area for each degree temperature
difference between the hot and cold fluid.
Typical coefficients are shown on pages
50 & 51.
1. Heat moves to exchanger wall
2. Heat moves through exchanger
wall
3. Heat moves into cool fluid
HEAT EXCHANGERS
22 HEAT EXCHANGER AREA

D. Area

The final factor that affects the flow of heat
is the area of the exchanger. An exchanger
with 10 tubes would obviously transfer twice
as much heat as one having 5 tubes. The area
of an exchanger is the total external area of
the tubes in the unit.
Table II on page 52 shows the external
tube area per linear meter [foot] of tubes most
commonly used in heat exchangers.

Example

An exchanger has 300 tubes 20 mm dia and 6 m long [ #/4 in. dia x 20 ft long]. What is the total
surface area?
Solution:

SI UNITS ENGLISH UNITS

Number of tubes 300 300

Length of each tube 6m 20 ft
Total length of tubing 300 x 6 = 1800 m 300 x 20 = 6000 ft
Size of tubes 20 mm 3/4 in.
Unit area of tube (Page 52) 0.0628m 2/m 0.1963 sq ft/ft
Total area of tubes = 1800 x 0.0628 = 6000 x 0.1963
= 113 m2 = 1178 sq ft

Problem 3

A glycol cooler has 250 - 25 mm diameter tubes 6 m long [1 in. dia. x 20 ft long].

The total surface area is _________________________.

To summarize, heat transfer depends on 3 factors:

1. Temperature difference of the fluids.

2. Coefficient of the exchanger.
3. Surface area of tubes or plates.

HEAT EXCHANGERS
 HEAT EXCHANGER DUTY 23

E. Duty coefficient, and temperature difference, are

known, and we want to determine the area.
You recall we said that the heat transfer in The formula can be rearranged to calculate
an exchanger was called its duty, and that the the area:
amount of heat that will transfer in an ex-
Duty '
changer is determined from the following equa- Area =
(∆T)(Coeff)
tion:

Duty = (∆T)(Coeff)(Area) Now that the factors that affect the duty of
an exchanger have been covered, let’s apply
When designing new exchangers, the duty, them to some exchanger problems.

Example:

A crude oil cooler operates at conditions shown below: The exchanger has 240 tubes 20
mm dia 12 m long [ 3/4 in. dia., 40 ft long]. What is the duty of the exchanger?

OIL OUT WATER OUT

38°C 49°C
[100°F] [120°F]

32°C 82°C
[90°F] 12 m [40 ft] [180°F]
WATER IN OIL IN

240-20 mm [ #/4 in] Tubes

Solution:
We will use the formula Duty = (∆T)(Coeff)(Area)
Calculate ∆T: 38°C Oil 82°C
∆T = 38 - 32 = 6°C [100°F ] W [ 180°F ] ∆T = 82 - 49 = 33°C
[∆T = 100 - 90 = 10°F ] 32°C V 49°C [∆T = 180 - 120 = 60°F ]
[ 90°F ] WATER [ 120°F ]
Average ∆T = 332+ 6 = 39
2
= 19.5°C [ 60 +2 10 = 702 = 35°F ]

HEAT EXCHANGERS
24 HEAT EXCHANGER DUTY

Sl UNITS ENGLISH UNITS

Coefficient, (Page 50) 340 60

Calculate area:
Number of tubes 240 240
Length of tubes 12 m 40 ft
Total length of tubing 12 x 240 = 2880 m 40 x 240 = 9600 ft
Tube diameter 20 mm 3/4 in
Unit area of tubes (page 52) 0.0628 m 2/m 0.1963 sq ft/ft
Total area of tubes 2880 x 0.0628 9600 x 0.1963
= 181 m 2 = 1884 sq ft
Heat Exchanger Duty Equation = (∆T)(Coeff)(A) (∆T)(Coeff)(A)
Substitute in equation (19.5)(340)(181) (35)(60)(1884)
Duty 1 200 030 watts 3 956 000 Btu/hr

Problem 4

Determine the duty of the following lean/rich amine exhanger.

LEAN FOUL
AMINE OUT AMINE OUT
70°C 99°C
[158°F] [210°F]

60°C 110°C
[140°F] 9 m [30 ft] [230°F]
400 Tubes LEAN
FOUL
DIA = 16 mm [%/8 in] AMINE IN
AMINE IN

AVERAGE TEMPERATURE DIFFERENCE __________COEFFICIENT _________

AREA _________ DUTY__________

HEAT EXCHANGERS
 PRESSURE DROP
F. Pressure Drop
We said earlier that flow through the
tube and shell sides should be turbulent in
order to have the maximum temperature dif-
ference between the hot and cold fluids. In
order to have turbulent flow, a relatively high
velocity must be maintained. The net result is
that each fluid will have a pressure drop as
it flows through the exchanger. The pressure
on the outlet end will be less than that on the
inlet end for each of the two fluids.
Most exchangers are designed for a
pressure drop of 35 - 70 kPa [5 - 10 psi] The
pressure drop is often a good tool for
troubleshooting problems on an exchanger. A
low pressure drop indicates a low flow, or
possibly ruptured tubes.
A high pressure drop indicates a high
flow rate or corrosion, scale, wax, hydrate or
plugging.
To accurately measure pressure drop,
differential pressure gauges should be in-
stalled as shown above. Use of pressure
gauges on the inlet and outlet streams to
SHELL FLUID OUT
TUBE FLUID IN
PRESSURE DROP MEASUREMENT
25
determine pressure drop is usually not accu-
rate enough to detect a change in the magni-
tude of 15-30 kPa [2.5 -5 psi].
Differential pressure readings should
be taken when an exchanger is new or after
cleaning, and noted in some obvious place so
that future differential pressure readings can
be compared with the readings when the unit
was in good condition.
G. Actual Heat Transfer
Up to this point, our discussion has cov-
ered the theoretical aspects of heat exchang-
ers. In other words, the amount of heat that
should transfer in an exchanger is based on
the area, average temperature difference of
the fluids, and the coefficient. But, how do we
know if the actual heat transfer is the same as
the theoretical rate?
The amount of heat transfer to raise or
lower the temperature of a fluid when there is
no condensation or vaporization is determined
from the following equations:
TUBE FLUID OUT
SHELL FLUID IN
HEAT EXCHANGERS
26 ACTUAL HEAT TRANSFER

ACTUAL HEAT TRANSFER EQUATIONS

SI UNITS ENGLISH UNITS
Heat Transfer watts=0.28 (kg/hr)(Temp Chg)(Ht Cap) Btu/hr=(wt, lb/hr)(Temp Chg)(Ht Cap)
Where: 0.28 Factor to convert kJ/hr to watts —
Temp Chg Inlet temp - Outlet Temp°C Inlet temp - Outlet temp, °F
Heat Capacity kJ of energy to heat 1 kg 1°C Btu of energy to heat 1 lb 1°F
Ht Cap Water 4.19 kJ/kg 1.0 Btu/lb
Ht Cap H/C 2.1 kJ/kg 0.5 Btu/lb

The heat capacity in English units is often heat capacity of liquid hydrocarbon varies from
called specific heat. Its value for hydrocarbon 1.9 to 2.3 [0.45 to 0.55]. For our purposes,
gases varies from 1.7 to 4.2 [0.4 to 1.0] depend- we will use an average value of 2.1 [0.5] for
ing upon the temperature and pressure. The hydrocarbon gas or liquid.

Example

A hot water heater holds 160 kg

[350 Ib] of water that enters at a
temperature of 32°C [90°F] and is
heated to 65°C [ 149°F] in one
hour. Determine the heat transfer.

Fuel

SI UNITS ENGLISH UNITS

Heat Transfer Equation: (0.28)(Weight)(Temp Chg) x (Wt)(Temp Chg)(Ht Cap)

(Ht Cap)
Weight of water 160 kg/hr 350 Ib/hr
Temperature change, 65-32 = 33°C 149-90 = 59 °F
Heat capacity of water 4.19 1.0
Subst in Equation (0.28)(160) (33) (4.19) (350) (59) (1.0)
Duty: = 6194 Watts = 20 650 Btu/hr

Problem 5

What will the duty be in the above example if the water is heated to only 52°C [125°F]?

______________________________________

HEAT EXCHANGERS
 ACTUAL HEAT TRANSFER IN LIQUID 27

1. Conversion of Liquid Volume to sure flow in volume. It is necessary to convert

Weight volume to weight in order to calculate the
As you have noted from the above ex- amount of heat that transfers.
ample, fluid weight must be known in order to The following equation is used to convert
calculate heat transfer. Most flow meters mea- liquid volume to weight:

Weight/hr = (Volume/hr)(Density of Water)(Relative Density of Liquid)

WATER DENSITY
SI UNITS ENGLISH UNITS
1000 kg/m3 or 1 kg/l 8.33 lb/gal or 350 lb/bbl

Example
Calculate the weight of liquid flowing and heat transfer in the crude oil cooler shown below.

Crude Oil
Out Water Out

38°C
[100°F]

58°C
[136°F]
Oil Flow = 3000 m3/d [ 19 000 b/d]
Water In Rel Density = 0.8 Crude Oil In
Heat Capacity = 2.1 [0.5]

SI UNITS ENGLISH UNITS

Flow per day 3000 m 3/d 19 000 b/d

Flow per hour 3000 = 125 m 3/hr 19 000 = 792 bbl/hr
24 24
Density of water 1000 kg/m 3 350 Ib/bbl
Subst in Weight Equation 125 x 1000 x 0.8 792 x 350 x 0.8
Weight flow 100 000 kg/hr 221 760 Ib/hr
Heat Transfer Equation (0.28)(Wt)(Temp Chg)(Ht Cap) (Wt)(Temp Chg)(Ht Cap)
Oil temp change 58 - 38 = 20°C 136 -100 = 36°F
Heat Capacity 2.1 0.5
Subst in equation (0.28)(100 000) x (20) x (2.1) (221 760) x (36) x (0.5)
Exchanger duty 1 176 000 Watts 3 992 000 Btu/hr

HEAT EXCHANGERS
28 ACTUAL HEAT TRANSFER IN GAS

Problem 6

A gasoline cooler in a gasoline plant operates as shown below. Weight per hour is
_______ Duty is _______.
GASOLINE OUT WATER OUT
40°C
[104°F]

GASOLINE COOLER 120°C

[250°F]
Flow = 115 l/min [30 gpm]
WATER IN GASOLINE iN
Rel. Density = 0.75
Heat Capacity = 2.1 [0.5]

2. Conversion of Gas Volume to Weight

If one of the fluids in an exchanger is gas, the equations for calculating the weight per hour
are:
EQUATIONS TO CONVERT GAS VOLUME TO WEIGHT
SI UNITS, KG/HR ENGLISH UNITS, LB/HR

Gas Weight = (0.05) (Flow, m3/d) (Gas Rel Dens) (3.18) (Flow Mcf/d) (Gas Rel Dens)

Gas flows in the above equations are daily rates, which most flow meters indicate.

Example
Gas having a relative density of 0.65 flows through a cooler at a rate of 2 000 000 m 3d
[70 000 Mcf/d]. Inlet temperature is 120°C [ 248°F] and outlet temperature is 37°C [98°F]. The
heat capacity of the gas is 2.1 [ 0.5 ]. Calculate the weight of gas and the duty of the exchanger.

SI UNITS ENGLISH UNITS

Flow rate 2 000 000 m 3/d 70 000 Mcf/d

Gas relative density 0.65 0.65
Subst in Weight Equation (0.05) (2 000 000) (0.65) (3.18) (70 000) (0.65)
Gas weight = 65 000 kg/hr = 144 690 Ib/hr
Heat Transfer Equation (0.28)(Wt) (Temp Chg) (Ht Cap) (Wt)(Temp Chg)(Ht Cap)
Subst in equation (0.28)(65 000) (120 - 37) (2.1) (144 690) (248-98) (0.5)
Heat transfer 3 172 260 watts 10 852 000 Btu/hr

HEAT EXCHANGERS
 HEAT OF VAPORIZATION OR CONDENSATION 29

Problem 7

Weight of gas flow per hour is ____________ .

Actual heat transfer is ____________.

HOT
GAS IN

110°C
[230°F]

36°C
[97°F] GAS COOLER
Flow = 1 000 000 m3/d = [35 000 Mcf/d]
GAS Relative Density = 0.62
OUT Heat capacity = 2.1 kJ/kg [0.5 Btu/lb]

3. Heat of Vaporization or of vaporization. It is obviously the same as

Condensation the heat that must be removed when a gas
condenses.
As we have previously mentioned, 4.19 kJ
of heat is required to raise the temperature of HEAT OF VAPORIZATION OR
1 kg of water by 1°C [1 Btu is required to heat CONDENSATION
1 lb of water 1°F ]. Water boils at 100°C [212°F
SI UNITS ENGLISH UNITS
]. After the temperature of water is raised to its
boiling point, 2257 kJ of heat must be added Water 2257 kJ/kg 970 Btu/lb
to boil 1 kg of water [970 Btu of heat must be Hydrocarbon 350 kJ/kg 150 Btu/lb
added to boil 1 lb of water]. There is no
temperature change when water boils; the In most gas cooling situations, some hy-
temperature of the steam that forms is at drocarbon and/or water condenses as gas is
exactly the same as that of the boiling water. cooled. This must be considered when deter-
The heat energy that must be added to a mining to total heat transfer when gas is
liquid to change it to a gas is called the heat cooled.

HEAT EXCHANGERS
30 HEAT OF VAPORIZATION OR CONDENSATION

Example

In the gas cooler example on page 28, 5% of the hydrocarbons in the gas condense. How much
heat is removed from condensation, and what is the total heat transfer in the exchanger.

120°C
[248°F]

37°C
[98°F]
GAS COOLER
Flow = 2 000 000 m3/d [70 000 Mcf/d]
GAS
Rel. Density = 0.65
OUT

Sl UNITS ENGLISH UNITS

Weight of gas (page 28) 65 000 kg/hr 144 690 Ib/hr

% H/C condensation 5% 5%
Weight of condensate 65 000 x 0.05 144 690 x 0.05
= 3 250 kg/hr = 7 235 Ib/hr
Heat of Vaporization 350 kJ/kg 150 Btu/lb
Heat removed by condensation 3250 x 350 7 235 x 150
= 1 137 500 kJ/hr = 1 085 250 Btu/hr
watts = 1 137 500 x 0.28
318 500 watts
Heat removed when gas is
cooled (Example P. 28) 3 172 260 watts 10 852 000 Btu/hr
Total Heat Transfer 3 490 760 watts 11 937 250 Btu/hr

Problem 8
Ten percent condensation occurs in the gas cooler in problem 7. The total heat of
condensation is _______________. The total exchanger duty is _______________.

In calculating the actual duty of an ex- condense or vaporize because the percent of
changer, it is usually best to determine the vaporization or condensation not always
duty based on the fluid that does not partially known. In exchangers using water as the

HEAT EXCHANGERS
 HEAT EXCHANGER DUTY 31

cooling fluid, the water flow rate and tempera-
ture change are used to determine the
duty.
The actual duty of an exchanger is calcu-
lated when we have reason to believe an
exchanger is not performing as it should.
We will first calculate the amount of heat
that actually transfers using the water flow
rate and temperature rise. The next step is to
calculate the theoretical amount of heat the
exchanger will transfer using the exchanger
equation, Duty = (∆T)(Coeff)(Area). We will
then compare the two rates.

Example:

A gas cooler had been cooling gas to a temperature of 38°C [100°F ]. The outlet gas temperature has slowly
risen to 43°C [109°F ]. We want to determine whether or not the exchanger is transferring as much heat
as it should. Present conditions are as follows:

Sl UNITS ENGLISH UNITS

Actual Heat Transfer, Duty=0.28 (Wt/hr)x(Temp Chg)x(Ht Cap) (Wt/hr)(Temp Chg)(Ht Cap)
Weight of water per hour (200 m 3/hr) (1000 kg/m 3) (880 gpm) (60 min/hr) (8.33 lb/gal)
= 200 000 kg/hr = 440 000 Ib/hr
Water Temperature change 45 - 32 = 13°C 113 - 90 = 23°F
Heat capacity water 4.19 1.0
Subst in equation, Heat transfer (0.28)(200 000) (13) (4.19) (440 000) (23) (1.0)
Calculate tube area: = 3 050 320 Watts = 10 120 000 Btu/hr
Tube size/length 20 mm/12 m 3/4 in/40 ft
Number of tubes 300 300
Total length of tubes 12 x 300 = 3 600 m 40 x 300 = 12 000 ft
2
Unit tube area (P-52) 0.0628 m /m 0.1963 sq ft/ft
Total tube area 3 600 x 0.0628 = 226 m2 12 000 x 0.1963 = 2356 sq ft
Av Temp Difference, ∆T 11+60 = 35.5°C 19+108 = 63.5 °F
2 2
Heat Exchanger duty Duty = ∆T x Coeff x Area
equation:
Coefficient (page 50) 450 80
Substitute In equation 450 x 226 x 35.5 80 x 2355 x 63.5
Theoretical duty 3 610 350 watts 12 000 000 Btu/hr
Actual duty from water flow 3 050 320 watts 10 120 000 Btu/hr

HEAT EXCHANGERS
32 HEAT EXCHANGER DUTY
The theoretical duty is almost 20% more
than the actual duty, which means that the
exchanger should cool the gas more than it is
doing. The only way the theoretical duty can
change is for the area to change (from plugged
tubes, for example); or for the coefficient to
change due to scale build-up or other fouling;
or for the temperature difference to change —
hot fluid is not as hot, or cool fluid is not as
cool.
In any event, the calculations show that
the exchanger is not transferring as much
heat as it should. The indications are that
tubes are fouled from dirt, scale, plugging,
etc. This can be confirmed by taking pressure
drop measurements on both gas and water
streams. The stream showing a pressure
drop above normal is probably the fouled side
of the exchanger.
There are other possible causes for the loss
of exchanger duty which should be checked
before shutting the unit down:
1. If the gas contains condensable hydrocar-
bons or moisture, it will accumulate in the
lower part of the exchanger on the shell
Problem 9
The gas cooler described in problems 8 on page 30 has operating conditions as
shown below.
7 000 kPa
[1 000 psi]
27°C 36°C
[81°F] [97°F]
GAS
OUT
Theoretical duty ________________________. Will it perform satisfactorily in the
service described in prolem 8? ________
HEAT EXCHANGERS
side and have the effect of plugging the
tubes that the liquid covers. Open a drain
valve on the bottom of the exchanger to
check for liquids. This should be done with
caution as liquid hydrocarbons at operat-
ing pressure may be volatile.
2. If lubrication oil from a compressor is
present in the gas, it may form a film on the
outside of the tubes and reduce the flow of
heat. This situation usually builds up slowly
over a period of time. It lowers the ex-
changer coefficient.
Suppose in the previous example, that the
calculated theoretical duty and actual duty
were within 5% of each other. This would
indicate the exchanger was okay. The prob-
able cause of an increase in outlet gas tem-
perature is from a higher gas flow rate and/or
a lower water flow rate.
In calculating the actual heat transfer in the
previous example, we used the water flow and
temperature change rather than the gas flow.
This gives a more accurate heat transfer rate,
particularly if there is some condensation on the
gas side.
HOT
GAS IN
110°C 43°C
[230°F] [110°F]
GAS COOLER
Flow = 1 000 000 m3/d = [35 000 Mcf/d]
Relative Density = 0.62 Number of tubes = 200
Tube length/diameter = 9m/16mm [30 ft/%/8 in.]
 III. APPLICATION OF EXCHANGERS
Heat exchangers are generally used for
one of three reasons:
1. To transfer heat in order for a process to
occur.
2. To conserve energy.
3. To cool a hot stream.
Some examples of each are:
1. Process exchangers
a. Reboilers on fractionation towers
and glycol strippers.
b. Reflux Condensers on Fractionators.
c. Gas Chillers.
2. Conserve energy
a. Gas-to-Gas exchangers.
b. Lean Glycol to Rich Glycol
exchangers.
c. Lean Amine to Foul Amine
exchangers.
d. Lean Oil to Rich Oil exchangers.
e. Fractionator preheaters.
3. Coolers
a. Radiators.
b. Compressor gas coolers.
c. Product coolers.
Selection of the type of exchanger to use
in a particular service is usually a matter of
economics. However, selection may be dic-
tated by circumstances. For example, if a
process cooler is needed in a location that has
no water, an aerial cooler would be selected.
TUBE BUNDLES FOR SHELL AND TUBE EXCHANGERS
33
A. Shell and Tube
The most widely used exchanger in pro-
cess plants is the shell and tube type. It can be
designed in a variety of configurations and
tailored to do a specific job. Special materials
for low temperature or corrosive service can
be used. They can be made long or short,
horizontal or vertical. The advantage of shell
and tube type exchangers over other types is
that since they are designed for a specific
application, they are more likely to perform
satisfactorily than other types.
The disadvantages of S and T units is that
they are expensive, and have a limited reuse
value in another location.
B. Hairpin
Hairpin exchangers are usually used when
the surface area requirement is less than 40
m2 [400 sq ft]. They are made in standard
sizes. Since standard size units must be se-
lected to fit the particular heat transfer service,
the exchanger may or may not perform as
required by the process. They are less expen-
sive than S and T exchangers in smaller sizes.
Probably the largest single use of hairpin
exchangers is on packaged process equip-
ment, such as gas dehydrators, refrigerated
hydrocarbon recovery plants, gas dehydra-
tors, refrigerated hydrocarbon recovery plants,
gas sweetening plants, etc.
HEAT EXCHANGERS
34 APPLICATION OF EXCHANGERS

The advantages of the hairpin exchangers temperature approach of 11°C [20°F] is about
are: the best that can be done. This means that the
outlet process fluid temperature will be at least
1. Low cost.
11°C [20°F] above ambient air temperature.
2. Ease of maintenance.
3. Ease of adding additional units. Aerial coolers must be carefully located in
4. Can easily be used in another application. a plant so that they do not circulate air that has
5. Good delivery. been warmed from a nearby heater or engine.
They should be on the upwind side of any heat
The disadvantages of hairpin exchangers source. They should be located above walls or
are: buildings that might divert the flow of air out of
1. May not perform to process requirements. the exchanger back to the intake side of the
2. Limited selection of metals. fan.
3. They are larger and take up more space.

C. Aerial Coolers
Aerial coolers are used when no other
process coolant (such as water) is available.
Some common applications of aerial coolers
are:
1. Engine radiators.
2. Process coolers on packaged equip-
ment and offshore platforms.
3. Fractionator condensers.
The main disadvantage of aerial coolers
is that the temperature of fluid out of the AERIAL COOLERS
cooler is limited by ambient air temperature. A IN PROCESS PLANT

TWO HAIRPIN EXCHANGERS IN SERIES

HEAT EXCHANGERS
 APPLICATION OF EXCHANGERS
D. Plate Type Exchangers
Plate type exchangers are one of the most
versatile type of exchangers because the
surface area can be changed by adding new
plates or removing plates from an existing
unit. In addition, they require less floor space
for installation and access for maintenance.
Each plate is separated from the next one
by the thickness of a gasket, so plugging can
occur if one of the fluids contains solid mate-
rials. The gaskets are also a possible source
of leakage, so the units are generally not used
at pressures above 2070 kPa [300 psi]. If one
of the fluids is a hydrocarbon or combustible
material, the unit should be located in an area
where a fluid leaking from a gasket will not be
ignited from a nearby engine, heater, or other
source of ignition.
Each plate in the exchanger is corrugated to
assure turbulent fluid flow. Since the plates are
only a gasket thickness apart, heat travels quickly
from the hot fluid to the cold one. Consequently,
the heat transfer coefficient is more than that in
a shell and tube exchanger, and the plate area
is much less.
PLATE FIN EXCHANGER
35
The temperature approach in a shell and
tube exchanger is seldom less than 5.5°C
10°F]. It can be as low as 1 °C [ 2 °F ] with a
plate type exchanger. If the exchanger is
used in a heat conservation service (such as
a Lean Glycol-to-Rich Glycol Exchanger in a
dehydration plant) the lower temperature ap-
proach will result in fuel saving.
E. Plate-Fin Exchangers
Plate-fin exchangers are usually made of
aluminum. They are used in low temperature
service in which stainless steel tubes would
be required to withstand the temperature. The
plate fin construction is more cost effective
than shell and tube using stainless steel. The
exchangers have close tolerances between
internal parts, so that they will act as filters to
remove solid particles from process fluids.
The particles may be removed by back flowing
the exchanger providing it is done when the
particles are still near the inlet part of the
exchanger.
HEAT EXCHANGERS
36 APPLICATION OF EXCHANGERS

Problem 10
Indicate the type of exchanger to use in the following applications:
APPLICATION TYPE
a. Lean Glycol to Rich Glycol operating
below 1400 kpa [ 200 psi ]. __________________
b. Inlet Gas-to-Outlet Gas exchanger in gasoline plant.
Operating pressure is 5200 kPa [ 750 psi ] , and
temperatures are -17 to 38°C [0 to 100°F]. __________________
c. Jacket water cooler on an engine. __________________
d. Gas to gas exchanger in cryogenic plant. __________________

PLATE TYPE EXCHANGER

HEAT EXCHANGERS
 IV. OPERATION OF EXCHANGERS 37

A. Shell and Tube, Hairpin, Plate Type,
and Plate Fin
In most cases, exchangers are put in
service by simply opening the process fluids
through them. The fluid with a temperature
closest to ambient should be opened first to
prevent the possibility of a thermal shock. If
the hot fluid is 55°C [l00°F] warmer than the
cold one, the flow of hot fluid should be
opened gradually to prevent shocking the
tubes with a sudden surge of heat.
If either of the fluids is a liquid, the ex-
changer should be checked to see that there
is not a gas pocket in the liquid side. This is
done by closing a valve in the liquid outlet line,
opening a valve in the liquid inlet line, and
opening a vent valve at the highest point on
the exchanger. The vent valve is kept open
until a steady stream of liquid flows out.
When an exchanger is shut down, the fluid
with the temperature closest to ambient is
shut in last. If fluids will remain in the ex-
changer during the shutdown period, valves in
the fluid outlet lines should be left open to
provide relief for possible pressure build-up in
one or both fluids when the unit is not in
service.

SHELL SIDE TUBE SIDE

FLUID OUTLET FLUID OUTLET
BEFORE START-UP, FILL
EXCHANGER WITH LIQUID
BY VENTING AIR OR GAS.
Vents VENT VENT

TO START-UP, FIRST OPEN FLOW

OF FLUID HAVING TEMPERATURE
CLOSEST TO AMBIENT.
SHELL SIDE
TUBE SIDE FLUID INLET
FLUID INLET

EXCHANGER START-UP PROCEDURE

HEAT EXCHANGERS
38 OPERATION OF AERIAL COOLERS

Most Reboilers have temperature control-
lers that regulate the flow of hot fluid in the
tubes. The temperature controller can be put
in service when the shell side liquid level is
above the tubes, and the tubes have been
warmed up by slowly admitting the hot tube
side fluid.
Routine operating checks of S & T ex-
changers are:
1. Observe fluid inlet and outlet tempera-
tures and determine the cause of a change
from normal.
2. Observe the pressure drop on each side
by reading pressure gauges, and deter-
mine the cause of change from normal.
3. Reduce or increase the fluid flow as needed
to obtain the desired temperatures. For
example, open the flow of water to coolers
in the summer, and close it in the winter.
4. If the exchanger is not insulated, and the
shell side fluid is a liquid, feel along the top
for an area with a higher or lower tempera-
ture than the rest of the unit. A hot or cold
area (depending upon whether the shell
side liquid is being heated or cooled) indi-
cates a vapor pocket. It is corrected by
opening a vent valve on the top of the
exchanger.
B. Aerial Coolers
Aerial coolers are started in the following
sequence:
1. Start the fan. Check for vibration or un-
usual noises.
2. Open fluid through the tubes.
3. Adjust louvers as necessary to hold outlet
temperature at its proper point.
On shut down, fluid is blocked in, and then
the fan is turned off.
Routine operating checks are:
1. Observe the cooler inlet and outlet tem-
peratures and determine the cause of a
change.
2. Adjust the louvers or other air flow controls
as necessary to hold the proper fluid outlet
temperature.
3. Check for leaks in the tubes or headers.
4. Check the fan for noise and vibration.
5. Check tube fins for damage or obstruction.
6. Periodically check the fan blades for speed,
pitch, and scale or dirt accumulation.

Problem 11
A. When a shell and tube exchanger is put in service, the first fluid to open is:
1. __ Hot fluid 3. ___ Fluid with temperature closest to ambient
2. __ Cold fluid 4. ___ Either fluid
B. When S & T exchanger is shut down, the last fluid to block in is:
1. __ Hot fluid 3. ___ Fluid with temperature closest to ambient
2. __ Cold fluid 4. ___ Either fluid
C. List the sequence for starting an aerial cooler.
______ Start fan
______ Open fluid through tubes

HEAT EXCHANGERS
 V. TROUBLESHOOTING EXCHANGER PROBLEMS 39

A. Shell and Tube and Plate Type appears to be a problem is the inlet and outlet
Exchangers temperature of each fluid using accurate ther-
The heat that transfers in an exchanger mometers. If temperature readings indicate a
equals: problem, check the flow rate of each fluid to
confirm that it is about normal.
Duty = (Temp. Diff.)(Coeff)(Area) If flows are within their normal operating
When a problem occurs in an exchanger, range, the next step is to determine whether
one or more of the three factors has declined. the problem is on the shell or tube side of the
The symptoms are: the hot fluid is not being exchanger. An increase in pressure drop al-
cooled as much; the cold fluid is not being most always occurs on the fouled side.
heated as much; and the temperature ap- If water is one of the fluids in an exchanger
proach has increased. that is not transferring as much heat as it
Following are the most common causes of should, the problem is usually on the water
exchanger problems. side. Corrosion, scale, dirt accumulation, and
Troubleshooting an operating problem is growth of fungus or other material can occur
a process of checking each likely cause, and on the water side. This type of fouling gener-
eliminating each until the culprit is found. It is ally builds up over a period of several weeks,
generally best to check the easy causes first unless there is an upset in the water circulat-
— temperatures, pressure drops, flows, etc. ing system.
— and then go to the more difficult ones. Back washing a water cooler is often effec-
The first thing to check on an exchanger that tive in removing debris from the exchanger.
Heat Transfer Factor Cause of Decline Corrective Action
Coefficient Dirt or slime on tube surface. Back wash
Scale on inside tube surface. Rod, drill or jet clean tubes.
Scale or dirt on outside of tubes. Clean with chemicals.
Ice or hydrate has coated tubes. Inject methanol. This will
not help if tubes are com-
pletely plugged.
Lube oil from compressor has Drain oil from exchanger.
coated tubes
Tubes plugged from dirt, scale, Back wash, rod, drill, or jet
Area fungus. clean.
Tubes plugged from hydrate, ice Warm-up above hydrate or
freezing temperature.
Tubes plugged from wax. Warm up above cloud point
Flow of one or both fluids is not 1. Increase flow.
Temperature turbulent. 2. Install turbulators inside
Difference tubes.
Inlet temperature of hot fluid is lower Adjust temperatures to
or low temperature fluid is warmer. normal.

HEAT EXCHANGERS
40 TROUBLESHOOTING EXCHANGER PROBLEMS
Water usually flows on the tube side.
The type of fouling is determined by re-
moving the heads and visually inspecting the
tubes. Tubes can be cleaned by using a
water-cooled drill, or with a special tool that
has high pressure jets that blast scale or other
material from the tube surface.
If the fluid in the fouled side of the ex-
changer is something other than water, the
cause of fouling must be determined. Hydrate
formation in gas coolers, and wax formation in
crude oil coolers are fairly easy to spot. Hy-
drate will occur in a gas stream containing
free water when the temperature is lowered to
the hydrate formation point. This can occur in
a gas cooler when the inlet temperature of the
cooling fluid is below the hydrate formation
temperature. Wax may form in a crude oil
cooler if the inlet temperature of the cooling
fluid is below the cloud point of the oil.
Hydrate or wax are removed by stopping the
flow of cooling fluid and continuing flow of the hot
fluid until the exchanger warms up.
If the shell side of an exchanger is fouled
REMOVABLE U-TUBE BUNDLE
HEAT EXCHANGERS
from scale or corrosion or coke, an acid or
chemical solution is usually circulated
through the shell side to clean it. Specialists
in this type of work should be consulted to
select the proper chemical and the proce-
dures for using it.
The best method of dealing with scale or
corrosion is one of prevention by injecting
inhibitors into the stream to prevent scale or
corrosion.
A leak in an exchanger results in high pres-
sure fluid entering the low pressure stream. A
large leak will cause a pressure rise in the low
pressure fluid, which is usually obvious from
pressure gauge readings, or a reduction in flow
of the low pressure fluid.
A small leak may not result in a noticeable
rise in pressure of the low pressure fluid. It is
confirmed by taking a sample of low pressure
fluid on the exchanger outlet and checking it
for the presence of high pressure fluid. For
example, suppose a leak occurs in a crude oil/
water cooler, where the oil pressure is more
than the water pressure. A sample of water
leaving the exchanger would con-
tain oil.
If each fluid is the same compo-
sition, such as a gas-to-gas ex-
changer, a laboratory analysis of a
sample of low pressure outlet fluid
may be required to detect the pres-
ence of the high pressure fluid in the
stream.
If a leaking tube is confirmed, the
exchanger is shut down and the heads
removed. Pressure is applied to the
shell side and the tube or tubes that
have shell fluid blowing out are
plugged by driving in tapered metal
plugs on each end of leaking tubes.
 TROUBLESHOOTING
TROUBLESHOOTING PROCEDURE
CAUSE OF LOSS OF DUTY
1. Low flow rate of one or both fluids.
2. Inlet temperature of one or both
fluids has changed.
3. Vapor pocket in liquid side.
4. Exchanger is fouled from corrosion,
scale, dirt, or fungus build-up on
water side. Condition usually takes
several weeks to appear and gradually
worsens.
5. Gas cooler is plugged with hydrate.
Condition can exist even though
outlet gas temperature is above the
hydrate formation point if the cool-
ing fluid temperature is below the
hydrate formation point.
6. Crude oil cooler is plugged with
wax. Condition can exist even
though outlet oil temperature is
above its cloud point if the cooling
fluid temperature is below the cloud
point.
41
PROCEDURE TO CORRECT
Check flow rates. Raise to design.
Check temperatures. Correct if neces-
sary.
Vapor pocket is determined by feeling
the outside of the exchanger. The tem-
perature will be different around
the area of a vapor pocket. Vent vapor.
a. Verify condition by measuring
pressure drop.
b. Back flow side with high pressure
drop if possible.
c. Shutdown and clean fouled side.
Tube side can be rodded or jet
cleaned. Shell side usually re-
quires chemical circulation.
a. Verify cooling fluid is below the
hydrate formation point, and pres-
sure drop on plugged side has risen.
b. Stop flow of cool fluid until unit
heats up above hydrate forming
temperature.
c. Inject methanol into inlet gas
stream to prevent future hydrate
formation.
a. Verify cooling fluid temperature
is below cloud point, and pressure
drop is up on oil side.
b. Shut in or raise temperature of
cooling fluid and allow warm oil
to flow until exchanger warms up
above the cloud point.
HEAT EXCHANGERS
42 TROUBLESHOOTING

TROUBLESHOOTING PROCEDURE

CAUSE OF LOSS OF DUTY PROCEDURE TO CORRECT

a. Confirm leakage from pressure

7. One or more tubes are leaking.
observation or by analyzing low
The higher pressure fluid will flow
pressure fluid for presence of high
into the low pressure fluid.Pressure
pressure fluid.
on the low pressure side will usu-
b. Shutdown unit and plug leaking
ally rise.
tubes.

B. Aerial Coolers
cooler. Here is the procedure for finding
Three types of problems occur on aerial
the cause:
coolers:
a. Check for an increase in the flow rate
1. Mechanical difficulties with the driver,
or temperature of the inlet fluid.
pulley, speed reducer, blades, etc. These
are not exchanger problems, and will not
b. Check for proper air movement. See
be discussed here. They usually result in
that louvers are open, the fan is run-
excessive vibration.
ning at full speed, blades are clean and
pitch is proper, and fins are clean and
2. Insufficient movement of air across the
undamaged.
tubes. This is an exchanger problem that
is difficult to diagnose. The best solution
c. Check for tube leakage. A leak will
to the problem is one of prevention.
usually show a stain and may cause
the outlet air to look smoky. Of course,
a. Check the fan speed and replace belts
a severe liquid leak will drip to the
or make other repairs as needed.
ground and be obvious.
b. Keep the fan blades clean and set at
d. If the problem persists, internal corro-
the right pitch.
sion or tube plugging is indicated. It can
usually be confirmed by checking for
c. Keep the outside of the tubes clean.
an increase in pressure drop across
Fins should be washed when they be-
the tubes. Aerial coolers usually have
come obstructed with dirt.
4—8 passes. The pressure drop of
each pass should be checked to see if
3. The final problem is one of insufficient
one or more are higher than the others.
heat transfer. This shows up as an in-
crease in the fluid temperature out of the

HEAT EXCHANGERS
 TROUBLESHOOTING 43

Problem 12
a. Hot gas at a pressure of 6900 kPa [ 1000 psi ] from a compressor passes through an aerial
cooler. Ambient temperature is 5 °C [ 41 °F ]. Gas temperature out of the exchanger has
risen 10°C [ 18°F ] above its normal point. The probable cause is ___________________
It is confirmed by measuring _______________________________________________
The condition is corrected by_______________________________________________
b. Process conditions at rich amine-to-lean amine exchanger in a gas sweetening plant
have changed as follows: Flow rate of each stream entering the exchanger has not
changed.
Normal operating conditions:

LEAN RICH
AMINE OUT AMINE OUT
68°C 35 kPa 50 kPa 93°C
[155°F] [5 psi] [7 psi] [200°F]

525 kPa
[75 psi]

57°C 107°C
[135°F] [225°F] 50 kPa
[7 psi]
RICH LEAN
AMINE IN AMINE IN
Present operating conditions are as follows:
LEAN RICH
AMINE OUT AMINE OUT
42 kPa 40 kPa
63°C 91°C
[6 psi] [5 psi]
[145°F] [198°F]
525 kPa
[75 psi]

57°C 105°C
[135°F] [225°F] 56 kPa
[8 psi]
RICH LEAN
AMINE IN AMINE IN

What appears to have happened? ______________________________________________

_________________________________________________________________________
How would you confirm it? ____________________________________________________

HEAT EXCHANGERS
44 TROUBLESHOOTING

Problem 12
c. Indicate whether the outlet temperatures in the following exchangers are higher,
lower, or unchanged.
Process Condition Hot Fluid Cold Fluid
1. Flow Rate Normal Lower
Inlet Temp Normal Normal
Outlet Temp ____________ ____________
2. Flow Rate Higher Normal
Inlet Temp Normal Normal
Outlet Temp ____________ ____________
3. Flow Rate Normal Normal
Inlet Temp Higher Normal
Outlet Temp ____________ ____________
4. Flow Rate Normal Normal
Inlet Temp Normal Lower
Outlet Temp ___________ ___________

C. Locked Sidestream Heaters Examples of this application are sidestream

Fractionating towers often have sidestream reboilers on demethanizers in cryogenic gas
heaters to add process heat to the vessels. plants.

Liquid flows from chimney to

heater. Liquid is partially CHIMNEY
vaporized in heater.

HEATING
FLUID
OUTLET
SIDESTREAM
HEATER

Stream out of heater is gas

and liquid. It returns to tower
to the tray below the chim- HEATING
ney. FLUID FRACTIONATING
INLET TOWER

NORMAL FLOW AT CHIMNEY TRAY

HEAT EXCHANGERS
 TROUBLESHOOTING 45

Liquid flows by gravity from the tower
through the heater. Downflowing liquid col-
lects in a chimney tray. This liquid flows through
the heater, where itemperature is raised
enough to vaporize some of the stream, and
the combined vapor liquid stream flows back
to the tower below the chimney tray. The level
of liquid in the chimney provides the head
pressure required to overcome the pressure
drop in piping and the heater.
If the pressure drop in the piping and hater
is more than the height of liquid in the chimney
tray, the liquid level will rise around the chim-
ney and overflow into the lower portion of the
tower. The net effect of liquid overflowing in
the chimney is to by-pass the heater. This will
result in less heat input to the tower, which in
turn will raise the content of top product in the
bottom product.
Another effect of a locked heater is that the
heating fluid which provides process heat in the
heater is not cooled as much as normal.
One way of eliminating this problem is to
inject a stream of gas into the process line out
of the heater. The gas lift action should restore
normal liquid flow to the heater and stop
overflow down the chimney. After tempera-
tures return to normal, which indicates the gas
lift action is working, the injection gas rate
should be slowly reduced until no gas flows.
Injection gas should be warm gas at a
pressure above that of the fractionating tower.
A 25 mm [1 in] line is usually large enough to
supply the volume of gas needed. Flow is
regulated with a valve in the line. A few min-
utes of gas injection is usually all that is
required.

When Reboiler is locked, liquid

overflows in the chimney instead of
flowing to the Reboiler.

Temp will rise

when Reboiler locks.

HEATING
FLUID
OUTLET SIDESTREAM
HEATER
INJECTION
GAS
Open injection gas to gas
lift heater outlet stream and HEATING
restore circulation. FLUID INLET FRACTIONATING
TOWER

FLOW OF INJECTION GAS TO RESTORE FLOW IN LOCKED HEATER

HEAT EXCHANGERS
46 VI. LOW TEMPERATURE EXCHANGER PROBLEMS
Heat transfer is one of the most critical
processes in a refrigerated or cryogenic gas
processing plant. Recovery of product de-
pends upon cooling the gas as low as pos-
sible. Over 80% of the cooling occurs in
exchangers. Consequently, heat exchangers
must operate properly in order to get the
maximum production.
In this section we will concern ourselves
with the exchangers in the gas cooling sys-
tem. Operating and troubleshooting other pro-
cess exchangers has been covered.
A. Inlet Gas-to-Outlet Gas Exchangers
The function of these exchangers is to recover
the refrigeration in the cold gas leaving the plant
by transferring it to the inlet gas stream. These
exchangers are usually designed for about 5°C
[10°F] temperature approach. To put it another
way the exchangers have approached within 5°C
[10°F] of recovering 100% of refrigeration in the
cold gas.
It is important that the performance of cold
gas exchangers in a new plant be evaluated
as soon as possible after start-up to establish
the actual performance of the unit to use as a
basis for future comparison.
In a refrigerated lean oil gas plant the inlet
gas stream usually contains enough moisture
for hydrate to form in the gas-to-gas exchanger.
Glycol is injected in the inlet end of the ex-
changer to prevent hydrate from forming in the
unit. The quantity of glycol that is injected, and
the manner in which it is injected, can have a
significant effect on the coefficient of the ex-
changer. This, in turn, will effect the amount of
heat transfer that occurs. Injecting more glycol
than is necessary, will lower the amount of heat
transfer.
The procedure for finding the ideal glycol
rate is not an easy or pleasant one. It is a
matter of starting with a high rate and slowly
HEAT EXCHANGERS
cutting back until hydrate forms, and then
slightly increasing the rate. The presence of
hydrate is indicated in two ways:
1. The temperature approach increases due
to a loss of heat transfer.
2. The pressure drop of the inlet stream (tube
side) increases.
When hydrate forms, it usually blocks the
flow of gas through some of the tubes. Conse-
quently, increasing the glycol injection rate
will not help because no flow is passing through
the plugged tubes. You have to melt the
hydrate by shutting down the refrigeration unit
and let the exchanger heat up until the hydrate
melts.
Gas entering a cryogenic gas plant is
supposed to have the moisture removed in a
dehydrator so that freeze-up should not oc-
cur. However, an upset in the dehydrator may
result in some moisture slippage, which will
usually freeze in one or more of the gas
exchangers. If the freeze is detected in its
early stage of formation, methanol injection
into the inlet gas will correct the condition
providing there is gas flow to carry the metha-
nol to the point of freeze-up. A total ice block-
age of part of an exchanger will require warm-
up to melt the ice or hydrate.
B. GAS CHILLER
The same principles that apply to freeze-ups
in the Gas-to-Gas Exchanger apply to the
Chiller. In addition, two other operating prob-
lems are often encountered in it:
1. Questionable level of refrigerant in the
shell side.
2. Accumulation of lube oil on the outside of
the tubes.
 GAS CHILLER 47

1. Level Indication in Chiller
In order to get the maximum duty from a
Chiller, the level of refrigerant must be above
the tube bundle. Very little heat transfer will
take place in tubes that are not immersed in
liquid. However, determining the level of re-
frigerant in the exchanger is not an easy thing
to do. The refrigerant is boiling rather violently
in the shell side, so that it is almost a foam.
You know that if you place a pan of water
on your stove and heat it until it boils violently,
the level in the pan will rise, and will probably
boil over onto the stove. The same situation
occurs in the chiller. A gauge glass on the
refrigerant side is not exposed to the same
heat as the fluid inside the vessel. So, it is not
boiling and will show a lower level than that
inside the chiller. Its level will be that of the pan
set on the stove before it started boiling,
whereas, the level inside the exchanger will
be the level after boiling started. Consequently,
a gauge glass is not an accurate measure of
the level of refrigerant in the chiller.
Since the guage glass is not an accurate
means of determining the level of refrigerant
inside the chiller, the question arises: how do
I know where to hold the level? The answer is:
at the point of maximum process cooling. The
function of the chiller is to cool a gas or liquid
process stream. You adjust the level of refrig-
erant up and down until you find the point at
which the process stream is cooled to the
lowest temperature. This is the proper refrig-
erant control point, regardless of where the
level is in the sight glass.
2. Lubricating Oil in Chiller
The refrigerant that flows to the Chiller comes
from a compressor. Most compressors require
some lubrication in the compressor cylinders.
Some of the lube oil injected in the cylinders will
end up in the liquid refrigerant. The lube oil will
dissolve in the refrigerant at ambient tempera-
ture; however, it is less soluble at the tempera-
ture in the Chiller. Consequently, it will separate
from the refrigerant in the Chiller.
If propane is the refrigerant, the lube oil
will settle in the bottom of the Chiller; if freon
is the refrigerant, the lube will collect on the
top of the refrigerant in the Chiller. In either
case, the boiling that occurs in the Chiller

REFRIGERANT
VAPOR
GAS
INLET
Level of boiling
refrigerant inside
chiller will be higher
than that in gauge
glass.

GAS LIQUID
OUTLET REFRIGERANT

CHILLER

HEAT EXCHANGERS
48 GAS CHILLER

will agitate the fluid in the vessel so that
some of the lube oil will be dispersed through-
out the vessel. Oil becomes viscous at low
temperatures, and it will tend to collect on
the tubes, and act as an insulation to pre-
vent the flow of heat. The duty of the Chiller
will decrease, and the outlet gas tempera-
ture will not be as low as it should be.
Several devices are available to remove
lube oil from refrigerant. We will not attempt to
describe them, but merely point out that they
should be in operation at all times.
Even though you use some form of oil
removal device, some lube oil will usually
find its way into the Chiller. The only way to
remove it is to drain it when the Chiller is
shut down. Consequently, each time the
unit is down, you should drain oil that has
accumulated. Oil should be drained as soon
as possible after shutdown while the refrig-
erant is still cold. As the refrigerant heats up,
the oil will dissolve in it.
Draining the oil from a Chiller using pro-
pane is no problem because the oil will settle
to the bottom, and will flow out a drain line.
However, draining oil from a unit using freon is
more difficult. The oil is lighter than liquid
freon, and it will float to the top of the freon. It
may be necessary to adjust the level of freon
inside the Chiller until it is next to a skim
connection on the side of the vessel.

PROPANE
VAPOR

GAS
INLET

DRAIN

GAS OUTLET LIQUID PROPANE INLET

DRAIN LUBE OIL FROM BOTTOM OF CHILLER

USING PROPANE FOR REFRIGERANT

HEAT EXCHANGERS
 49

Problem 13

a. The symptoms of hydrate formation in a gas chilling exchanger are:

_______________________________________________________________________

b. Hydrate is removed by _____________________________________________________

_______________________________________________________________________
c. Excessive glycol injection in a gas chilling exchanger results in ______________________
_______________________________________________________________________
d. The level of refrigerant inside a chiller will be higher/lower/the same as the level shown in a
gauge glass.

e. Lube oil which collects in a chiller using freon is removed by ________________________

_______________________________________________________________________

HEAT EXCHANGERS
 50 TABLE l
TYPICAL EXCHANGER COEFFICIENTS

A. SHELL AND TUBE EXCHANGERS

WATER COOLERS SI UNITS ENGLISH UNITS

Gas at 700 kPa [ 100 psi] 226 watts 40 Btu
Gas at 3500 kPa [ 500 psi ] 310 watts 55 Btu
Gas at 7000 kPa [1000 psi] 512 watts 90 Btu
C 2, C3, C4 512 watts 90 Btu
Natural Gasoline 455 watts 80 Btu
Naphtha 455 watts 80 Btu
Kerosene 480 watts 85 Btu
Crude Oil 340 watts 60 Btu
Amine 790 watts 140 Btu
Air 115 watts 20 Btu
Water 1075 watts 190 Btu

WATER CONDENSERS
C2, C3, C4, 735 watts 130 Btu
Still Overhead 425 watts 75 Btu
Naphtha 425 watts 75 Btu
Amine Regenerator 595 watts 105 Btu

REBOILERS - STEAM 850 watts 150 Btu

REBOILERS - HOT OIL 595 watts 105 Btu

MISCELLANEOUS
Lean Oil/Gas 455 watts 80 Btu
Lean Oil/Rich Oil 515 watts 90 Btu
Gas/Gas at 700 kPa [ 100 psi ] 285 watts 50 Btu
Gas/Gas at 3500 kPa [ 500 psi ] 340 watts 60 Btu
Gas/Gas at 7000 kPa [ 1000 psi ] 395 watts 70 Btu
Gas Chiller - Propane Refrigerant 395 watts 70 Btu
Lean Oil Chiller - Propane Refrigerant 540 watts 95 Btu
Lean Amine/Foul Amine 705 watts 125 Btu

HEAT EXCHANGERS
 TABLE 1 51
TYPICAL EXCHANGER COEFFICENTS
B. AERIAL COOLERS
Approximate Air
Coefficients Temperature Rise

SI Units English Units °C °F

CONDENSERS
Propane, Butane 512 watts 90 Btu 20 35
Still Overhead 425 watts 75 Btu 20 35
Steam 0-300 kPa [0-50 psi] 705 watts 125 Btu 40 70
Naphtha 425 watts 75 Btu 17 30
Amine Stripper Overhead 455 watts 80 Btu 33 60
Natural Gasoline 455 watts 80 Btu 17 30
Freon 425 watts 75 Btu 20 35

COOLERS
C 2, C3 512 watts 90 Btu 20 35
Natural Gasoline 455 watts 80 Btu 17 30
Naphtha 395 watts 70 Btu 17 30
Gas at 700 kPa [ 100 psi] 226 watts 40 Btu 11 20
Gas at 3500 kPa [ 500 psi] 340 watts 60 Btu 17 30
Lube Oil 85 watts 15 Btu 6 10
Glycol 85 watts 15 Btu 20 35

Note: SI coefficients are watts of heat transfer per square meter per °C of temperature
difference.
English coefficients are Btu of heat transfer per hour per square foot per °F of
temperature difference.

Coefficients are based on bare tube area and not area of fins.

HEAT EXCHANGERS
52

TABLE II

EXTERNAL SURFACE AREA OF HEAT EXCHANGER TUBES

SI UNITS ENGLISH UNITS

Tube Size, Square Meters Tube Size Square Feet

Outside of External outside of external
Diameter, area per diameter, area per
mm m of tube in. ft of tube

12 0.0377 1/2 in. 0.1309

14 0.0440 5/8 in. 0.1636
16 0.0503 3/4 in. 0.1963
18 0.0565 7/8 in. 0.2291
20 0.0628 1 in. 0.2618
25 0.0785 1 1/4 in. 0.3272
30 0.0942 1 1/2 in. 0.3927
35 0.1100 2 in. 0.5236
40 0.1257 2 1/2 in. 0.6545
50 0.1571
60 0.1885

Examples:

A piece of 20 mm tubing 1 m long has an external surface area of 0.0628 square meters.

A piece of 1 in. tubing 1 ft long has an external surface area of 0.2618 square feet.

HEAT EXCHANGERS
 VALIDATION 53
HEAT SI UNITS
EXCHANGERS Trainee
1. The gasoline cooler shown below has 2. Two years after start-up, operating con-
300 tubes, 18 mm in diameter and 10 m ditions are as follows.
long. Total surface area _______m 2. Actual duty is _____________ watts.
Average temperature difference Is exchanger transferring as much heat
_____°C. Coefficient _____________ as it should? _______________
Theoretical duty___________watts. If not, what appears to be the problem?
Temperature approach _____°C. Actual _______________________________.
duty based on water flow and tempera- What should be done? ____________
ture change is _______watts. Pressure _______________________________
drop on water side_____kPa. ______________________________.
Pressure drop on gasoline side ____kPa.
GASOLINE WATER
OUTLET OUT GASOLINE
OUTLET WATER OUT
38°C 49°C
42 kPa 35 kPa 44°C 49°C
42 kPa 70 kPa

32°C 115°C 32°C 115°C

WATER IN 135 m3/hr GASOLINE INLET WATER IN 125 m3/hr GASOLINE INLET

3. The 3 factors that affect heat transfer in an exchanger, and an example of a

cause of reduction in each are:
Factor
1. ___________________________
2. ___________________________
3. ___________________________
4. Indicate whether the following fluids should flow inside or outside the tubes:
Fluid
Highest Pressure
Highest Temperature
Most Corrosive
Gas When Other Fluid is Liquid
Cause of reduction
_________________________________
_________________________________
_________________________________
Should Flow
Inside, Outside, Doesn't Matter
Inside, Outside, Doesn't Matter
Inside, Outside, Doesn't Matter
Inside, Outside, Doesn't Matter

5. When putting an exchanger in service, the first fluid to open is ________________

__________________________________________________________________

6. The temperature of gas out of a gas cooler has risen. The temperature approach has
not changed. What has happened? ______________________________________
__________________________________________________________________

HEAT EXCHANGERS
 54 SOLUTION TO PROBLEMS
SI UNITS
1. A. 3 D. 2 2. Temp diff left end = 32 - 26 = 6°C
B. 6 E. 4 Temp diff right end = 12 + 4 = 16°C
16 + 6
C. 5 F. 1 Avg temp diff = = 11°C
2
Temperature approach = 6°C

3. No. Tubes = 250 Tube diameter = 25mm

Tube length = 6m Unit area = 0.0785 m2/m
Total tube length = 250 x 6 = 1 500m Total area = 1 500 x 0.0785 = 117.75m2
4. Avg temp diff = 10 +2 11 = 10.5 Area = 400 x 9 x 0.0503 = 181.08m2
Coefficient = 705 Duty = (10.5)(181.08)(705) = 1 340 445 watts
5. Wt = 160 kg/hr; temp change = 52 -32 = 20°C; Ht Cap = 4.19
Duty = 0.28 (160)(20)(4.19) = 3 754 watts
6. Wt/hr = (115 l/m)(60 min/hr)(1 kg/l)(0.75) = 5 175 kg/hr
Duty = (0.28)(5 175)(120 - 40)(2.1) =243 432 watts
7. Wt/hr = (0.05)(1 000 000)(0.62) 31 000 kg/hr
Duty = 0.28 (31 000)(110 - 36)(2.1) = 1 348 872 watts
8. Wt/hr gas = 31 000 kg/hr
% Condensation = 10%
10%
Wt/hr condensate = (31 000)( ) = 3 100 kg/hr
100
Heat of condensation = (3 100)(350) = 1 085 000 kJ/hr
watts = (1 085)(0.28) = 303 800 watts
Total duty = (1 348 872) x 303 800 = 1 652 672 watts
9. Use HEX duty equaion, Duty = ∆T x Coeff x Area
9 + 67
∆T = = 38°C; Coeff = 512; Area = 200 x 9 x 0.0503 = 90.54 m2
2
Theor. Duty = 38 x 512 x 90.54 = 1 765 546 watts. Actual duty from problem 8 is less than
theoretical duty. Exchanger will perform satisfactorily.
10. a. Glycol Exchanger Plate Type
b. Gas/gas Exchanger above -17°C Shell & Tube
c. Jacket water cooler Aerial
d. Cryogenic gas/gas Exchanger Plate Fin
11. A 3 Fluid with temperature closest to ambient C 1 Start fan
B 3 Fluid with temperature closest to ambient 2 Open fluid through tubes
12. a. Hydrate or freeze up
Confirm with high pressure drop measurment
Correct by closing louvers, stop fan, and let gas flow continue until ice or hydrate melts.
Methanol injection may help.
b. Temp of rich amine out is higher, which could be due to lower flow.
Temp of lean amine out is lower, which could be due to cool rich amine leaking into the
lean stream.
Pressure drop on rich side is less - indicates less flow.
Pressure drop on lean side is more - indicates more flow.
It appears high pressure rich amine is leaking into lean amine. Confirm by analyzing
lean amine outlet stream.
c. HOT FLUID COLD FLUID
1 Higher Higher
2 Higher Higher
3 Higher Higher
4 Lower Lower
13. a. High pressure drop; outlet gas d. Higher.
temperature not as cold. e. Skimming from top of freon.
b. Warm up by shutting down refrigeration.
c. Lowers coefficient. Less cooling.
HEAT EXCHANGERS
HEAT VALIDATION 55
EXCHANGERS ENGLISH UNlTS
Trainee

1. The natural gasoline cooler shown below
has 300 tubes, 5/8 in. in diameter and 30
ft long.
Total surface area _________sq ft. Av-
erage temperature difference _____°F
Coefficient ___________Theoretical
duty _____________Btu/hr.
Temperature approach _____°F. Actual
duty based on water flow and tempera-
ture change is ______________Btu/hr.
Pressure drop on water side____psi. Pres-
sure drop on gasoline side ____psi.
GASOLINE WATER
OUTLET OUT
2. Two years after start-up, operating con-
ditions are as follows.
Actual duty is __________Btu/hr.
Is exchanger transferring as much heat
as it should? _________.
If not, what appears to be the problem?
__________________________________________
______________________________.
What should be done? ____________
______________________________
______________________________.
GASOLINE WATER
OUTLET OUT
110°F 120°F
6 psi 10 psi

100°F 6 psi 5 psi 120°F

90°F 240°F
90°F 240°F WATER GASOLINE
IN INLET
WATER IN 500 GPM GASOLINE INLET 450 GPM

3. The 3 factors that affect heat transfer in an exchanger, and an example of a cause of
reduction in each are:
Factor Cause of reduction
1. ___________________________ _________________________________
2. ___________________________ _________________________________
3. ___________________________ _________________________________
4. Indicate whether the following fluids should flow inside or outside the tubes:
Fluid Should Flow
Highest Pressure Inside, Outside, Doesn't Matter
Highest Temperature Inside, Outside, Doesn't Matter
Most Corrosive Inside, Outside, Doesn't Matter
Gas When Other Fluid is Liquid Inside, Outside, Doesn't Matter
5. When putting an exchanger in service, the first fluid to open is ________________
__________________________________________________________________
6. The temperature of gas out of a gas cooler has risen. The temperature approach has
not changed. What has happened? ______________________________________
__________________________________________________________________

HEAT EXCHANGERS
56 SOLUTION TO PROBLEMS
ENGLISH UNITS
1. A. 3 D. 2 2. Temp diff left end = 90 - 80 = 10°F
B. 6 E. 4 Temp diff right end = 40 - 10 = 30°F
C. 5 F. 1 10 + 30
Avg temp diff = = 20°F
2
Temperature approach = 10°F
3. No. Tubes = 250 Tube diameter = 1 in
Tube length = 20 ft Unit tube area = 0.2618 sq ft/ft
Total tube length = 20 x 250 = 5 000 ft Total tube area = 5 000 x 0.2618 = 1 309 sq ft
18 + 20
4. Avg temp diff = = 19° Area = 400 x 0.1636 x 30 = 1963.2 sq ft
2
Coefficient = 125 Duty = (19)(125)(1963,2) = 4 662 600 Btu/hr
5. Wt = 350 lb/hr; Temp change = 125 - 90 = 35°; Ht cap = 1.0;
Duty = 350 x 35 x (1.0) = 12 250 Btu/hr
6. Wt/hr = (30 gpm)(60 min/hr)(8.33 lb/gal)(0.75) = 11 245 lb/hr
Duty = (11 245)(250 - 104)(0.5) = 820 922 Btu/hr
7. Wt/hr = (3.18)(35 000)(0.62) 69 000 lb/hr
Duty = (69 006)(230 - 97)(0.5) = 4 588 900 Btu/hr
8. Wt/hr gas = 69 000
% Condensation = 10%
10%
Wt/hr condensate = (69 000)( ) = 6900 lbs/hr
100
Heat of condensation = (6 900(150) = 1 035 000 Btu/hr
Total duty = 4 588 900 + 1 035 000 = 5 623 900 Btu/hr
9. Use HEX duty equaion, Duty = ∆T x Coeff x Area
16 + 120
∆T = = 68°F; Coeff = 90; Area = 200 x 30 x 0.1636 = 981.6 sq ft
2
Theor. Duty = 68 x 90 x 981.6 = 6 007 392 Btu/hr. Actual duty from problem 8 is less than
theoretical duty. HEX will perform satisfactorily.
10. a. Glycol Exchanger Plate Type
b. Gas/gas Exchanger above 0°F Shell & Tube
c. Jacket water cooler Aerial
d. Cryogenic gas/gas Exchanger Plate Fin
11. A 3 Fluid with temperature closest to ambient C 1 Start fan
B 3 Fluid with temperature closest to ambient 2 Open fluid through tubes
12. a. Hydrate or freeze up. Confirm with high pressure drop measurment
Correct by closing louvers, stop fan, and let gas flow continue until ice or hydrate
melts. Methanol injection may help.
b. Temp of rich amine out is higher, which could be due to lower flow.
Temp of lean amine out is lower, which could be due to cool rich amine leaking into the
lean stream.
Pressure drop on rich side is less - indicates less flow.
Pressure drop on lean side is more - indicates more flow.
It appears high pressure rich amine is leaking into lean amine. Confirm by analyzing
lean amine outlet stream.
c. HOT FLUID COLD FLUID
1 Higher Higher
2 Higher Higher
3 Higher Higher
4 Lower Lower
13. a. High pressure drop; outlet gas d. Higher.
temperature not as cold. e. Skimming from top of freon.
b. Warm up by shutting down refrigeration.
c. Lowers coefficient. Less cooling.

HEAT EXCHANGERS
 PLP TRAINING MANUALS
NUMBER TITLE

F-1 Basic Units of Measurement

F-2 Measurement of Energy
F-3 Hydrocarbons
F-4 Fluid Flow

E-1A Centrifugal Compressors Part 1

E-1B Centrifugal Compressors Part 2
E-2 Piston Type Compressors
E-3 Centrifugal Pumps
E-4 Reciprocating Pumps
E-5 Gas Engines
E-6 Fractionators
E-7 Heat Exchangers
E-8 Indirect Fired Heaters
E-9 Pneumatic Process Instruments
E-10 LACT Units
E-11 Lean Oil Absorbers
E-12 Separators

P-1 Cryogenic Gas Plants

P-2 Glycol Dehydration Process
P-3 Contactor in Dehydration Plant
P-4 Stripper in Dehydration Plant
P-5 Molecular Sieve Dehydration Process
P-6 Adsorber in Dehydration
P-7 Crude Oil Emulsion Treating
P-8 Hydrate Inhibition
P-9 Mechanical Refrigeration
P-10 Amine Sweetening Process
P-11 Contactor in Sweetening Process
P-12 Stripper in Sweetening Process
P-13 Stabiblizing Crude Oil & Condensate

M-1 Flow Measurement

M-2 The Gas/Oil Well
M-3 Oilfield Safety

305 WELLS FARGO DR., SUITE 4 • HOUSTON, TEXAS 77090 • (281) 444-7632 • FAX: (281) 586-9876
E-MAIL: PetroLearning@aol.com

HEAT EXCHANGERS