Sandvik Materials Technology

Rob Foster - Product Manager

•Based out of Stafford, TX
•Responsible for:
– Fabricators (Shell and Tube & Air Coolers)
– Engineering Companies
– Refineries
– Duplex Materials
– Boiler Tubing
– Coal Fired Furnaces
•Office: (281) 275-4821
•Cell: (713) 824-6768
•Email: rob.foster@sandvik.com
•www.smt.sandvik.com

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 Itinerary For Training
• Definitions of Heat Exchangers
• Terminology
• Principals
• Different Types of Heat Exchangers
• Engineering a Heat Exchanger
• Manufacturing a Heat Exchanger
• Conclusion
• Question Time

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 Definitions Of A Heat Exchanger
• Exchanger = To give something in return for something received; make an
exchange.
• A Heat Exchanger can be defined as a device that continuously transfers
heat from one medium to another without adding energy to the process.
• One of the most common forms of a Heat Exchanger is a radiator that we
use to heat our homes. By circulating the hot water or steam through the
radiator the surrounding air is heated thus warming the room.

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 Definitions Of A Heat Exchanger
• Another very familiar heat exchanger is a car radiator. Relatively cool air is
forced over the fins of the radiator thus cooling the water circulating through
it. This principal is known as convection heat transfer. This cool water is
then circulated through the water jackets that surround the cylinders
therefore ensuring the engine block never reaches dangerously high
temperatures.
• On a larger scale, heat exchangers are employed in many industrial
processes to carry out the same heating or cooling operation that we see
everyday in our homes and vehicles.

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 Terminology
• Baffle Plate. Also called support plate. Tubes pass through this plate
for support. Provides a blocked path for the shell-side medium,
forcing the medium across the tubes for better heat exchanger
performance.
• Baffle Spacing. The space between baffle plates on a tube bundle.
Baffle spacing is adjusted to achieve maximum heat exchanger
performance.
• End Plate. A cover that has been welded to the heat exchanger. Most
end plates are used on bonnet assemblies.
• Fixed Tube Sheet. A non removable tube sheet; the tube sheet on a
core assembly; or any tube sheet that is an integral part of the shell
assembly.
• Floating Tube Sheet. The tube sheet at one end of a removable-
tube bundle. The floating tube sheet always has a smaller diameter
than does the stationary version. The floating tube sheet moves freely
with the expansion and contraction of the tube bundle due to
temperature changes in operation.

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 Terminology
• Gasket. A sealing device used between two parts to prevent
leakage. Types include inside-the-bolt circle (no bolt holes) and full
face (with bolt holes and the same diameter as the flange).
• Impingement Plate. A small perforated- -plate or bar assembly
placed inside the shell-side nozzle, usually a dome-type nozzle. The
plate also can be attached directly to the bundle by being tack-
welded to the tie rods. The impingement plate protects and prolongs
tube life by breaking up and slowing down the shell side fluid, which
otherwise would erode the tubing.
• Nipple. A short piece of pipe threaded on both ends.
• Design Pressure. Also called maximum allowable operating
pressure. Used by engineers to calculate part thickness and heat
exchanger design. Generally, it is slightly higher than the most
severe condition or highest operating pressures seen by the heat
exchanger.

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 Terminology
• One, Two, Four Pass. The number of times the fluid passes
through the tube bundle. In a one-pass unit, the tube-side medium
passes through all the tubes once. In a two-pass unit, it passes
through one-half of the tubes and returns through the other half. A
four-pass unit goes through approximately one-quarter of the tubes,
down and back four times. Greater-than-one pass heat exchangers
are referred to as multipass units.
• Operating Pressure. The pressure a heat exchanger is actually
operating at while in use.
• Outer-Tube Limit (OTL). The diameter created by encircling the
outermost tubes in a tube layout. Engineers use the design OTL to
calculate clearances between bundle parts. The actual OTL is
usually a few-thousandths less than the design OTL.
• Test Pressure. Generally 1.5 times the design pressure. It is used
during a hydrostatic test that detects leaks at any joint on the heat
exchanger.

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 Terminology
• Removable Bundle. A type of heat exchanger in which the tube
bundle can be removed from the shell pipe. This provides easy
cleaning of the shell side and a less expensive way of replacing worn
out tubes.
• Shell Assembly. The assembly into which the tube bundle fits. The
shell also contains the shell-side connections.
• Shell Head. A formed plate welded to the shell, or bonnet, pipe. It
can be many styles or shapes, including flanged and dished, elliptical,
ellipsoidal and hemispherical. Generally, as a head gets flatter, it gets
weaker; therefore, designers can use a flat-end plate or a thinner
formed head to do the same job.
• Shell Side. The side of a heat exchanger where the fluid circulates
around the outside of the tubes.
• Stationary Tube Sheet. The tube sheet at one end of a removable
bundle. It has a larger diameter than the floating tube sheet and is
held together in a permanent position between the bonnet and shell
flanges.

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 Terminology
• Tube Sheet. A plate that secures both ends of the tube in a heat
exchanger. Both the shell-side and tube-side mediums come in
contact with.

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 Terminology - Diagrams

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 Terminology - Diagrams
• Tube Bundle

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 Terminology - Diagrams
• Tubesheet

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 Principles of Heat Exchangers
The process of heat transfer through fluid-to-fluid heat exchangers is based on
basic properties of heat conduction. When two independent chambers or
circuits carrying fluids with a temperature difference are touching, the heat
always moves to cold, trying to find equilibrium. Two important factors in the
effectiveness of heat transfer are the amount of surface area that comes in
contact with the heat source and the materials used to conduct the heat.

Over the past decade, advancing heat exchanger technologies have been
penetrating the U.S. market. Paralleling the advances in technology are an
increasing interest in the cost benefits of efficient use of energy resources, as
well as other concerns about resource management.

The process fluid (in the form of a gas or a liquid) can flow inside or outside the
tubes. On the opposite side there is another fluid which serves to cool or heat
the process medium to the desired temperature and/or to recover heat to be
used elsewhere in the plant.

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 Principles of Heat Exchangers

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 Principles of Heat Exchangers

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 Different Heat Exchangers
Shell and tube heat exchangers are divided into three section. The
front end section or head, the shell and the rear end section or head.
There are several variations of each part. The following table shows
the different sections or variations:

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 Different Heat Exchangers

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 Different Heat Exchangers

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 Different Heat Exchangers

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 Different Heat Exchangers

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 Different Heat Exchangers

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 Exchangers Parts
• 1. Inlet (or outlet) tube side
• 2. Outlet (or inlet) tube side
• 3. Inlet (or outlet) shell side
• 4. Outlet (or inlet) shell side
• 5. Bonnet without partition wall
• 6. Fixed tube sheet
• 7. Shell
• 8. Straight tubes
• 9. Baffle plate
• 10. Bonnet with partition wall
• 11. Tube sheet
• 12. U tubes
• 13. Channel with partition wall
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• 14. Channel cover
• 15. Floating-head tube sheet
• 16. Floating-head backing
device
• 17. Floating-head cover
• 18. Shell cover
• 19. Shell nozzle
• 20. Liquid level connection
• 21. Liquid level connection
• 22. Weir
 Exchangers Types

Heat exchangers come in a large variety of types and sizes. Here are a few of the
most common ones.

Coil heat exchangers have a long, small-diameter tube placed concentrically

within a larger tube, the combined tubes being wound or bent in a coil. One fluid
passes through the inner tube, and the other fluid passes through the outer tube.

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 Exchangers Types
• This type of heat exchanger is robust—capable of handling high pressures
and wide temperature differences. However these exchangers tend to be
low-cost, they provide rather poor thermal performance as a consequence
of a small heat-transfer area. A coil heat exchanger may be the best choice
for low-flow situations, for the reason that the single-tube passage creates
higher flow velocity and a higher Reynolds number. These exchangers are
generally used to establish a fixed temperature for a process-stream sample
prior to taking measurements. These exchangers can also be used to
condense high-temperature stream samples.

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 Exchangers Types
Plate Heat Exchangers
Plate heat exchangers consist of a stack of parallel thin plates that lie between
heavy end plates. Each fluid stream passes alternately between adjoining plates
in the stack. The plates are corrugated for strength and to enhance heat transfer
by directing the flow and increasing turbulence.

These exchangers have high heat-transfer coefficients and area, the pressure
drop is also usually low, and they often provide very high efficiency. Nevertheless,
they have comparatively low-pressure capability.

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 Exchangers Types
Shell-and-tube heat exchangers consist of a bundle of parallel tubes that
provide the heat-transfer surface separating the two fluid streams. The
tube-side fluid passes axially through the inside of the tubes; the shell-side
fluid passes over the outside of the tubes. Baffles external and
perpendicular to the tubes direct the flow across the tubes and provide
tube support. Tube sheets seal the ends of the tubes, ensuring separation
of the two streams. The process fluid is generally placed inside the tubes
for ease of cleaning or to take advantage of the higher-pressure capability
inside the tubes. The thermal performance of such an exchanger generally
exceeds a coil type but is less than a plate type. Pressure capability of
shell-and-tube exchangers is usually higher than a plate type but lower
than a coil type.

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 Exchangers Types
• Coolers – are used to cool off the process medium, mostly with water, to
the desired temperature.
• Condensors - are used to condense the process medium on the tube
walls. In other words they are used to transition vapor to a liquid. This
type heat exchanger is common in distillation processes in oil refineries
as well as petrochemical and chemical industries.
• Evaporators - are used for the separation of liquids and solids, in
particular to recover a solute (e.g. chemicals) from the solvent, which is
often water. The pulp and paper industry is a large user of evaporation
equipment. Evaporators are also used in the production of table salt
(sodium chloride) and other salts, in caustic-chlorine production, in the
phosphate industry, and in food processing.
• Preheaters - are used to heat the process medium on a step by step
basis. They are often followed by one or more heat exchanges. Typical
examples are feedwater preheaters in the power industry, where steam is
used to preheat water before it enters the boilers.

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 Feedwater Preheater Bundle

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 Exchangers Types
• Reheaters are used to reheat process fluids to their useful temperature.
Chloride concentration can often take place in these heat exchangers due to
the refluxing of the fluids. Reheaters are often found in the petrochemical
and chemical industries.
• Reboilers are used to keep a process medium boiling. Reboilers are used
in crude oil distillation towers. Often times reboilers are used in conjunction
with a stripper for the purifying of process chemicals.
• Double Tube Heat Exchangers are a simpler and cheaper variant of the
shell and tube heat exchanger. It consists of a number of double tubes, one
inside the other. It is suitable for small heat exchangers (less than 20 m2
heat-transfer surface). These types of heat exchangers can take extremely
high pressures. Sometimes the tube walls are deformed or dimpled to
create turbulent flow for better heat transfer. In some cases welded tube
seams can crack during forming, hence seamless tubes are a better option.

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 Bank of Reboilers

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 Exchangers Types
• Steam generators are used in nuclear power plants to produce steam for
the production of electric energy.

• Air coolers are heat exchangers that have no shell. The tubes are usually
finned in order to increase the heat exchange surface area. Cooling air is
then blown over the fins. This type of exchanger is used to cool process
fluids in the same way as shell and tube coolers. Air coolers are preferred
when the process fluids are too hot to be practically cooled by water or
when suitable cooling-water sources or treatment facilities are not available.

• Plate Heat Exchangers are used in dairies and the food-processing

industry, but is also installed in the process industry for less demanding
applications. It consists of two end covers between which the required
number of plates (pressed in such a way that channels form when
assembled) are placed. Between the plates there are gaskets. The whole
package is closed with the aid of compression bolts.

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 Exchangers Types Inlet

Finned
tube Header

Header

Tube sheet

Tube sheet

Vigrous air draft, forced through the tube Outlet

bundle by the cooling fan

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 Engineering A Heat Exchanger
There are two main considerations when designing / engineering a heat
exchanger:
 Thermal Design
 Mechanical Design

During thermal design the aim is to calculate a necessary heat transfer

surface area that will enable the equipment to achieve its required heating
or cooling function

In a tubular heat exchanger the tubes provide the heat transfer interface
between the hot and the cold medium. Advanced computer software, used
in the thermal calculations, determines the necessary number of tubes.

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 Engineering A Heat Exchanger
• There are several important factors to be considered during thermal
design.

 Fluid characteristics
 film forming properties
 phase
 viscosity
 Fluid temperatures
 Fluid pressures
 Fluid flow rates
 Fluid pressure drop

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 Engineering A Heat Exchanger
• The aim of the mechanical design is to create a piece of equipment that will
fulfill the functions calculated during the thermal design. In the mechanical
design the heat exchanger is dimensioned so that it can cope with the
process pressure parameters. This may also dictate the use of specific
types of heat exchangers that are better able to handle certain pressure
scenarios.

• In mechanical design heat exchanger size, tube dimension, tube

arrangement (pitch), baffle placement and many other things are
considered.

• The most utilized set of guidelines for mechanical design of tubular heat
exchangers is TEMA (Standards of Tubular Exchanger Manufacturers
Association, USA). The pressure calculations are often made in conjunction
with national rules such as ASME section VIII.

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 Heat Exchanger Fabrication

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 Heat Exchanger Fabrication
Expanding Tubes in a Tubesheet

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 Heat Exchanger Fabrication
Expanding Tubes in a Tubesheet

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 Heat Exchanger Fabrication

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 Heat Exchanger Fabrication
Seal Welding a Tube To Tubesheet joint

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 Heat Exchanger Fabrication
Example of Seal Welded Tube to Tubesheet Joint

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 Bending of U-Tubes

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 U-Tubes

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 Overlaying a Tubesheet

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 Overlayed Tubesheet Partially
Finished

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 Heat Exchangers In Place

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 Examples of Heat Exchangers

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 Examples of Heat Exchangers

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 Heat Exchangers Pulled Out Of
Service

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 Heat Exchangers Pulled Out Of
Service

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 Conclusions
• Heat transfer equipment is found in all industries from bulk chemical
processing to domestic plumbing. The type of heat exchangers used vary
enormously from shell and tube, to fin fan air coolers, plate type exchangers
and modern compact exchangers. There are specialized types of
exchangers in the nuclear industry such as steam generators and special
kinds of heat exchangers for recovering heat from high temperature gases
called recuperators.

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 Questions

………………..? ? ?

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