Refurbishing of Heat and Shell Tube Heat Exchanger

BY
WHANNOU EZEKIEL ADEDOLAPO
EMAKPOR MELODYSTAR OVIE
SALAMI ITUNU

AIRCRAFT MAINTENANCE ENGINEERING SCHOOL

NIGERIAN COLLEGE OF AVIATION TECHNOLOGY
ZARIA

FEBRUARY 2024
Refurbishing of Heat and Shell Tube Heat Exchanger

BY

WHANNOU EZEKIEL ADEDOLAPO

AME/ND/2021/110

EMAKPOR MELODYSTAR
AME/ND/2021/109
 SALAMI ITUNU
AME/ND/2021/

A Group of Project Submitted To the Aircraft Maintenance Engineering School,

Nigeria College of Aviation Technology, Zaria
In Partial Fulfillment of the Award of the National Diploma in Aircraft Maintenance
Engineering

NIGERIA COLLEGE OF AVIATION TECHNOLOGY, ZARIA FEBRUARY, 2024

 DECLARATION
We declare that the work in this project entitled “Refurbishing of Heat and Shell
Tube Heat Exchanger” has been performed by us in the Aircraft Maintenance
Engineering School. The information derived from the literature has been greatly
acknowledged in the text and a list of references provided.

WHANNOU A. EZEKIEL ----------------------------

EMAKPOR O. MELODYSTAR ------------------------------

SALAMI ITUNU ----------------------------

 CERTIFICATION

This is to certify that this research work titled “Refurbishing of Heat and Shell Tube
Heat Exchanger” BY Whannou Ezekiel, Emakpor Melodystar, Salami Itunu
has met with the regulation governing the award of the National Diploma of the
Nigeria College of Aviation Technology, Zaria and is hereby
approved for its contribution and literary presentation
 ACKNOWLEDGEMENT
We would gladly like to express our deepest gratitude to GOD for making it possible
for us to be able to reach this stage in our lives, and to our dearest
and lovely parents that financed our education, our admirable instructors for lecturing
and instructing us, and broadening our knowledge on both the
theoretical and practical aspect on aircraft maintenance engineering,
 ABSTRACT
"WE express our gratitude to the dedicated team involved in the refurbishment of
the heat exchanger. Your commitment to excellence and expertise in handling
complex processes has significantly contributed to the successful enhancement of
its performance. Special thanks to each member for their invaluable efforts in
ensuring the efficiency and reliability of the heat exchanger."
 TABLE OF CONTENT
Title Page …………………………………………………………………………………. i
Declaration………………………………………………………………………………. ii
Certification…………………………………………………………………………….. iii
Acknowledge…………………………………………………………………………… iv
Abstract …………………………………………………………………………………. v
Table of Content …………………………………………………………………….. vi

CHAPTER ONE
1. Introduction ………………………………………………………………………… 1
1.1 Background of Study…………………………………………………………… 1
1.2 Research Motivation ………………………………………………………….. 2
1.3 Aim …………………………………………………………………………………….. 2
1.4 Objectives …………………………………………………………………………… 3
1.5 Research Scope …………………………………………………………………… 3

CHAPTEER TWO

2.0 Literature Review ……………………………………………………………….. 4

2.1 Overview ……………………………………………………………………………. 4
2.2 Historical Background …………………………………………………………. 4
2.3 Materials …………………………………………………………………………….. 7

2.3.1 Cleaning and Maintenance ………………………………………………

2.3.2 Enhancements and Modernization………………………………..
2.3.3 Testing and Quality Assurance:……………………………………………………………..
2.3.4 Documentation and Reporting ………………………………………………………………..
2.3.5 Timeline:…………………………………………………………….
2.4 Scope of the Project ………………………………………………………..

2.5 Method uses………………………………………………………………….

2.5.1 Welding ……………………………………………………..........
2.5.2 Drilling::…………………………………………………………….
2.5.3 Grinding::…………………………………………………………….
2.5.4 Filing ……………………………………………………………………………….
3.5.5 Paint ……………………………………………………………………………….

CHAPTER THREE
DIAGRAM AND WIRING CIRCUIT DIGRAM OF PROJECT
3.1 PROJECT DIAGRAM……………………………………………………………..
3.2 WIRING CIRCUIT DIGRAM……………………………………

CHAPTER FOUR
ANALYSIS OF RESULTS AND DISCUSSION
……………………………………………………………..
4.1 Results ……………………………………………………………………………….
4.2 Discussion ………………………………………………………………………….
4.3 Cost Analysis ………………………………………………………………………

CHAPTER FIVE
5.0 Conclusion and Recommendation ……………………………………..
5.1 Conclusion …………………………………………………………………………
5.2 Recommendation ……………………………………………………………...
References ……………………………………………………………………………….
 CHAPTER ONE
1.0 INTRODUCTION
1.1 Background of Study
The industrial sector heavily relies on heat exchangers for various processes, ranging
from chemical manufacturing to power generation. Heat and shell tube heat
exchangers play a crucial role in facilitating heat transfer between fluids. Over time,
these systems may experience degradation and inefficiencies, necessitating
refurbishment to maintain optimal performance. This project aims to address these
challenges and contribute to the overall sustainability of industrial processes.
Refurbishing a heat and shell tube heat exchanger is a complex and intricate process
that requires a comprehensive understanding of thermodynamics, fluid dynamics, and
materials engineering. In the realm of industrial heat transfer, these devices play a
pivotal role in various applications, ranging from power generation to chemical
processing.
The refurbishment of a heat and shell tube heat exchanger typically becomes
necessary due to factors such as deterioration of materials, fouling, or a decrease in
performance efficiency over time. Before delving into the details of the refurbishment
process, it is crucial to grasp the fundamental principles governing heat exchangers.
Heat exchangers are devices designed to transfer heat between two or more fluids.
The shell and tube configuration is a common design, featuring a shell encompassing
multiple tubes through which the heat exchange occurs. Understanding the
thermodynamics involved is essential for optimizing the performance of these heat
exchangers.
Over time, factors like corrosion, scaling, and fouling can significantly impact the
efficiency of a heat exchanger. This necessitates a meticulous refurbishment process
to restore the unit to its optimal functioning state. The refurbishment process involves
a series of steps, starting with a comprehensive inspection to identify the extent of
damage and assess the overall condition of the heat exchanger. Materials engineering
plays a critical role in the refurbishment process Selecting the right materials is
paramount to ensuring the longevity and efficiency of the heat exchanger after
refurbishment.
Fluid dynamics also comes into play during the refurbishment process. The design of
the tube layout, the velocity of the fluids, and the flow patterns within the heat
exchanger must be carefully considered. Computational Fluid Dynamics (CFD)
simulations may be employed to model and optimize fluid flow, enabling engineers to
make informed decisions about enhancements or modifications during the
refurbishment.
Refurbishing a shell and tube heat exchanger is a critical process aimed at restoring its
efficiency and performance. Heat exchangers play a pivotal role in various industrial
processes, including power generation. Over time, these heat exchangers may
experience wear and tear, corrosion, fouling, or other issues that can compromise
their effectiveness. Refurbishment becomes essential to extend the equipment's
lifespan, improve energy efficiency, and ensure optimal thermal performance.
Before delving into the refurbishment process, it is crucial to understand the basic
structure and function of a shell and tube heat exchanger. This type of heat exchanger
consists of a series of tubes bundled within a cylindrical shell. One fluid, known as the
process fluid, flows through the tubes, while another fluid, typically cooling water or
air, circulates around the outside of the tubes in the shell. Heat is exchanged between
the two fluids, facilitating the desired temperature change in the process fluid.
Refurbishing a shell and tube heat exchanger typically involves a comprehensive
assessment of its condition. This assessment includes inspecting the tubes for
corrosion, erosion, or fouling, examining the shell for integrity, and evaluating the
overall structural components Weld repairs or shell replacement may be required,
depending on the severity of the damage. Additionally, gaskets and seals between the
tubes and the tube sheets may need replacement to prevent leakage and ensure the
integrity of the heat exchanger.
Improvements in design and materials may be incorporated during the refurbishment
process to enhance the heat exchanger's efficiency and longevity. Advanced coatings,
such as corrosion-resistant alloys or polymer linings, may be applied to protect against
future corrosion and extend the equipment's service life.

Research Motivation
The need for pratical experiment on themodynamic (heat lost and heat share ) in the Aircraft
Maintenance Engineering School (AME School) hanger at the Nigerian College of Aviation
Technology, Zaria.

1.3 Aim
The primary aim of this project is to enhance the efficiency and sustainability of the
heat and shell tube heat exchanger through a systematic refurbishment process. By
addressing issues such as fouling and corrosion, the refurbished system is expected to
operate at optimal efficiency, resulting in energy savings and reduced environmental
impact

1.4 Objectives
1. The primary goal of this project is to refurbish the existing shell and tube heat
exchanger to enhance its performance, efficiency, and extend its operational
lifespan.
2. Installation of pump and rotarmeter, heater, welding ,and other plumbing
equipment
 CHAPTER TWO
2.0 LITERATURE REVIEW

2.1 Overview : This literature review explores the key aspects of refurbishing shell and
tube heat exchangers, focusing on methodologies, challenges, and advancements
in this critical area of heat transfer technology.
Heat Exchanger Fundamentals: Understanding the fundamental principles of heat
exchangers is essential for effective refurbishment. Heat exchangers operate on the
principles of heat transfer, typically involving fluids of different temperatures. The
literature review will delve into the basic concepts of heat exchanger design,
classifications, and working principles.

Common Issues in Heat Exchangers: Identifying common problems encountered in

heat and shell tube heat exchangers is crucial for determining the scope of
refurbishment. Literature will be reviewed to explore issues such as fouling, corrosion,
and thermal inefficiencies. This section will provide insights into the root causes of
performance degradation.

Refurbishment Techniques: Several techniques are available for refurbishing heat

exchangers, ranging from mechanical cleaning to the application of protective
coatings. The literature review will analyze these techniques, highlighting their
advantages, limitations, and applicability to different scenarios. Additionally,
advancements in refurbishment technologies will be explored.

Refurbishment Methodologies: Several methodologies are employed in refurbishing

shell and tube heat exchangers, each tailored to address specific issues. The most
common refurbishment processes include cleaning, repair, and replacement of
components. Cleaning methods range from chemical cleaning to mechanical methods,
aiming to eliminate fouling and corrosion deposits. Repair involves fixing or reinforcing
damaged components, while replacement entails the substitution of worn-out parts
with new ones.

Corrosion Protection and Mitigation: Corrosion poses a significant threat to the

integrity of shell and tube heat exchangers. Advances in corrosion protection and
mitigation techniques have been crucial in prolonging the service life of these devices.
Various protective coatings, such as epoxy and ceramic coatings, have been developed
to shield heat exchanger surfaces from corrosive environments. Additionally, the use
of corrosion-resistant alloys has gained prominence in enhancing the overall corrosion
resistance of heat exchanger materials.
Challenges in Refurbishment: Despite advancements in refurbishment technologies,
challenges persist in the process of restoring shell and tube heat exchangers. One
major challenge is identifying the extent of internal fouling and corrosion, as these
factors can significantly impact the heat exchanger's performance. Moreover, the
selection of appropriate materials for refurbishment is crucial, considering factors
such as compatibility with operating conditions, cost-effectiveness, and environmental
considerations.
Environmental Considerations: In the context of growing environmental awareness,
the refurbishment of shell and tube heat exchangers is increasingly being scrutinized
for its environmental impact. Efforts are underway to develop sustainable
refurbishment practices, emphasizing the use of eco-friendly materials, energy-
efficient processes, and responsible waste disposal methods. As industries strive for
increased efficiency and sustainability, the refurbishment of heat and shell tube heat
exchangers emerges as a critical aspect of process optimization. This project seeks to
contribute to this endeavor by providing a comprehensive analysis of the
refurbishment process, drawing on the principles outlined in the literature review. The
successful implementation of the project's aim will not only extend the operational life
of the heat exchanger but also promote environmentally conscious industrial
practices.

2.2 Historical Background

The refurbishment of heat and shell tube heat exchangers represents a critical
aspect of industrial maintenance and engineering, rooted in the evolution of heat
exchange technology and the imperative to optimize operational efficiency while
extending the lifespan of capital equipment. To understand the historical
background of this process, we must delve into the development of heat
exchangers, the emergence of shell and tube designs, and the evolution of
refurbishment practices.
The concept of heat exchange dates back centuries, with rudimentary systems used
for heating water and spaces in ancient civilizations. However, significant
advancements occurred during the Industrial Revolution in the 18th and 19th
centuries, driven by the need to efficiently transfer heat in steam engines and
industrial processes. Early heat exchangers consisted of simple designs, often
employing coils or plates to facilitate heat transfer between fluids.

The shell and tube heat exchanger, a cornerstone of modern industrial processes,
emerged in the late 19th century as engineers sought more efficient and scalable
solutions for heat exchange. This design features a series of tubes enclosed within a
cylindrical shell, with one fluid flowing through the tubes while the other flows around
them, allowing for efficient heat transfer across a large surface area. The versatility
and effectiveness of shell and tube heat exchangers led to their widespread adoption
in various industries, from power generation to petrochemical processing.

Over time, as industrial facilities aged and equipment endured prolonged use, the
need for refurbishment became evident. Refurbishing heat and shell tube heat
exchangers involves restoring or replacing components to ensure optimal
performance and reliability. The historical evolution of refurbishment practices
parallels advancements in materials science, manufacturing techniques, and
engineering standards.

Early refurbishment efforts focused primarily on repairing or replacing damaged tubes

and shells using conventional welding and machining methods. However, as industries
progressed, so did refurbishment techniques. Innovations in non-destructive testing
(NDT), such as ultrasonic testing and radiographic inspection, enabled more
comprehensive assessments of heat exchanger integrity, allowing for preemptive
maintenance and targeted repairs.

Moreover, advancements in materials engineering facilitated the development of

corrosion-resistant alloys and high-strength materials, enhancing the durability and
longevity of refurbished components. Techniques such as surface treatments and
coatings further improved resistance to fouling, erosion, and chemical degradation,
reducing the frequency of refurbishment cycles and extending operational lifespans.
2.3 Materials

Materials and Component Replacement:

 Replace damaged or corroded tubes, ensuring compatibility with the
existing system.
 Upgrade or replace shell components as needed for improved
performance.
 Installation of
 rotameters ---2
 Gasket
 Pump-2
 We need plumbing accessories
 Water heater element
 Water horse —1inch 5 length
 Gauge valve—3
 Clips— 10 pieces
 Perspect Glass
 silicon Gum -2
 3 quarter Piper half length 0
 ½ union connector
 ¾ white elbow
 2 white taps
 ½ gate valve
 Small plumbing gum
 ½ nipple
 ¾*1/2 socket
 Cleaning and Maintenance:
 Implement a comprehensive cleaning process to remove any fouling,
deposits, or impurities from the tubes and shells.
 Perform necessary maintenance activities, including tightening loose
connections and fixing leaks.
Enhancements and Modernization:
 Integrate modern technologies or improvements to enhance the heat
exchanger's overall efficiency.
 Consider incorporating advanced materials for increased heat transfer
capabilities.
Testing and Quality Assurance:
 Conduct rigorous testing to ensure the refurbished heat exchanger meets
specified performance standards.
 Implement quality assurance measures throughout the refurbishment
process.
Documentation and Reporting:
 Maintain detailed records of the refurbishment process, including
replaced components, testing results, and any modifications made.
 Provide a comprehensive report outlining the improvements and changes
made during the refurbishment.
Timeline: The project is expected to be completed within [insert timeframe], with
periodic updates and milestones communicated throughout the refurbishment process.
Budget: A detailed budget will be established based on the assessment findings and the
scope of work. Any deviations from the initial budget will be communicated and
approved in advance.
2.4 Scope of the Project: The scope of this project encompasses a thorough assessment
of the existing heat and shell tube heat exchanger, identification of specific issues
affecting its performance, and the implementation of targeted refurbishment
 strategies. The project will involve a multidisciplinary approach, integrating
mechanical, thermal, and materials engineering principles.
Inspection and Assessment:
 Conduct a thorough inspection of the current heat exchanger to identify
areas of corrosion, wear, or damage.
 Evaluate the integrity of tubes, shells, broken pipes and horse and
associated components.

2.5 Method uses

The methods used during the constriction are welding, punching, filling, drilling,
cutting, grinding, sand papering
Welding: Welding is the fusing or joining of two or more metals together using electric
current conducted through an electrode. There are different types of welding, the types
used during the carried project development is the arc welding. Arc welding uses an
electric phenomenon called arc discharge (an electric discharge phenomenon of gas)
and refers to current released in the air. In arc welding , positive voltage is applied to
the electrode and negative voltage is applied to the base materials
Drilling:
This is also a cutting process, where a hole is made or drilled into on solid materials (
metals, woods, plastics, composites materials) by the use of a drilling machine and a
drill bit
Plumbing: This is any system that conveys fluids for a wide range of
applications. Plumbing uses pipes, valves, plumbing fixtures, tanks, and other
apparatuses to convey fluids. Heating and cooling (HVAC), waste removal, and potable
water delivery are among the most common uses for plumbing

Filling: This is also a method of cutting. It entails the use of files to smooth
rough and sharp edges from cutting metals
Grinding: This is the method of reducing the size of a hard material or
sharpening of tools or metals to produce desired finesse of the work piece.
Grinding machine reduce or smooth out materials (work-piece) by abrasion
Paint: A liquid solution of pigment (coloring material) and solvent, which is applied on different
surfaces for decorative or protective reasons.

Types of Paints used

Aluminum Paint : Aluminum paint refers to a paint that is solvent-based and filled with
aluminum flake. It is a protective metallic finish use on well-prepared metal surfaces like storage
tanks, roofs and pipe work. This paint can withstand temperatures up to 302°F (150°C). It is a
good heat and light reflector as well as it resists water permeability.

Aluminum paint produces a genuine aluminum finish and it is highly resistant to rust and
corrosion. It is very suitable for restoring old or rusted aluminum or steel objects in industrial
areas. It is often used for coating industrial equipment and corrugated sheets in industrial areas.

Anticorrosive Paint : Corrosion resistant coatings protect metal components against

degradation due to moisture, salt spray, oxidation or exposure to a variety of environmental or
industrial chemicals. The anticorrosive paints impede or obstruct the corrosion by reducing the
direct access of air and water to the metal.
 CHAPTER THREE
DIAGRAM AND WIRING CIRCUIT DIGRAM OF PROJECT
4.1PROJECT DIAGRAM :

REAR VIEW
FRONT VIEW

SIDE VIEW

4.2WIRING CIRCUIT DIAGRAM :

 CHAPTER FOUR
ANALYSIS OF RESULTS AND DISCUSSION

4.1Introduction: Refurbishing a shell and tube heat exchanger involves a

comprehensive analysis of results and discussions to ensure the optimal
performance of the system. In this advanced-level discussion, we will delve
into key aspects of the refurbishment process, focusing on the results
obtained and the implications for the overall efficiency of the heat exchanger.
4.2Analysis of Results:
Thermal Performance: The primary objective of refurbishing a heat exchanger
is to enhance its thermal efficiency. The results should include a detailed
analysis of temperature differentials, heat transfer rates, and overall thermal
performance. Any improvements or deviations from the expected values must
be thoroughly examined.

Flow Characteristics: Fluid flow is a critical factor in heat exchanger

performance. The results should encompass flow rates, pressure differentials,
and velocity profiles. Any anomalies in flow patterns, such as turbulence or
restrictions, need to be highlighted and addressed.

Material Integrity: The refurbishment process involves inspecting and possibly

replacing components to ensure material integrity. Results should provide
insights into the condition of materials, corrosion levels, and the effectiveness
of any corrosion-resistant coatings applied during refurbishment.

Energy Consumption: Assessing the energy consumption of the heat

exchanger post-refurbishment is vital. Any reduction in energy requirements
or improvements in energy transfer efficiency should be thoroughly
documented. This analysis is crucial for industries aiming to enhance
sustainability and reduce operational costs.

4.3Discussion:
Root Cause Analysis: If the refurbishment was prompted by performance
issues, the discussion should delve into the root causes of the problems
identified. Whether it was fouling, corrosion, or other issues, a detailed
examination will guide future maintenance practices.
Impact on Operational Efficiency: Discuss how the refurbishment has
influenced the overall operational efficiency of the heat exchanger. This
includes any observed improvements in heat transfer rates, reduced pressure
drops, or enhanced fluid mixing capabilities. Quantify these improvements
wherever possible.

Lifecycle Cost Considerations: Evaluate the refurbishment in terms of its

impact on the heat exchanger's lifecycle costs. While upfront refurbishment
costs are incurred, discuss how these expenses compare to the potential long-
term savings in energy consumption and maintenance.
Compliance and Safety: Ensure that the refurbished heat exchanger complies
with relevant industry standards and safety regulations. Discuss any
modifications made to meet these standards and the implications for the safe
operation of the system.

Future Recommendations: Conclude the discussion by providing

recommendations for future maintenance practices or potential upgrades.
This could include suggestions for monitoring and preventive measures to
prolong the efficiency of the heat exchanger.

In summary, the analysis of results and discussion for the refurbishing of a

shell and tube heat exchanger demands a meticulous examination of thermal
performance, flow characteristics, material integrity, and energy consumption.
By providing a comprehensive discussion, stakeholders can make informed
decisions regarding the effectiveness of the refurbishment process and plan
for continued operational excellence
 CHAPTER FIVE

CONCLUSION AND RECOMMENDATION OF PROJECT

5.1In conclusion: the refurbishing of a shell and tube heat exchanger is a critical
process that plays a pivotal role in ensuring optimal performance and
efficiency in industrial settings. The meticulous examination of each
component, such as tubes, shells, and baffles, is imperative to identify
potential issues and address them effectively. Moreover, the choice of
materials and the application of advanced welding techniques during
refurbishment contribute significantly to the longevity and reliability of the
heat exchanger. a well-executed refurbishment process, incorporating
advanced materials and technologies, is fundamental to extending the
operational life of a shell and tube heat exchanger. By following these
recommendations and staying abreast of technological advancements,
industries can ensure the continued efficiency and reliability of their heat
exchange systems.
5.2Recommendations: for an effective refurbishing process include the utilization
of high-quality materials that can withstand corrosive environments, especially
if the heat exchanger is exposed to aggressive fluids. Employing cutting-edge
technologies, such as non-destructive testing methods, ensures a thorough
assessment of the equipment's integrity. Additionally, considering
enhancements in heat transfer surfaces and adopting modern design
improvements can lead to increased heat exchanger performance
Furthermore, it is essential to collaborate with experienced professionals or
engineering firms specialized in heat exchanger refurbishment. Their expertise
can provide valuable insights into the latest industry standards and best
practices, guiding the refurbishment process towards optimal outcomes.
Regular maintenance schedules and monitoring systems should also be
implemented to detect any potential issues early on, preventing costly
downtime and unexpected failures.