HEAT EXCHANGERS

Welcome to the
Knowledge
sharing module
on Heat
Exchangers & It's
Maintenance

NWECHI,BELOVED
Sheet 1
 AIM (objective)
 The intent of this session is aimed at
informing, refreshing and increasing the
knowledge base of the workforce, with
focus on heat exchanger and its
acceptable maintenance practice.
 Plant Equipment types:

Rotating Static
Pump
Pipe lines
Compressor. etc
Reactor Tank/Drum
Agitator
Column

Heat exchanger
 -WHAT IS Heat Exchangers ?
heat exchanger is a device built for
efficient heat transfer from one fluid to
another, where the fluids are separated by
a solid wall so that they don`t mix.

It is basically, for cooling or heating

of process fluid, with respect to process
requirement.

Hx facilitates the exchange of heat transfer

Q, it has two stream,s1,s2. This two
streams will be at temperature T1,T2(T1//
T2)
 -How does heat exchanger work?
Heat exchanger utilizes the fact that heat transfer occurs when there is a
difference in temperature. In a heat exchanger, there is a cold stream and
a hot stream. The two streams are separated by a thin, solid wall. The wall
must be thin and conductive in order for heat exchange to occur. Yet the
wall must be strong enough to withstand any pressure by the fluid.
•In a heat exchanger, heat is transferred from one fluid
to another either by direct contact or through an
intervening wall.

•Heat exchangers are used extensively

in engineering and include Shell & tube ,Plate,air cooled , etc

•Here is a simple flow diagram, showing how heat is transfer in exchanger.

 -Types of Heat Exchanger

Tubes and shell exchanger

Plate heat exchanger

Fine fan heat exchanger

etc

Sheet 14
 SHELL & TUBE

Shell and tube type Heat

Exchangers

Straight tube
fixed Floating U tube
tubesheet Head

Externally Internally
Outside clamped
sealed
Packed (split ring)
Lantern ring
 Shell and U- tube Bundle
Nozzle:shell side
outlet
Tube sheet
Nozzle:Shell side
inlet Tube

Channel
cover

Shell

Baffles

Pass partition
plate Nozzle:Shell side
Nozzle:Tube side inlet
outlet
 -PARTS
Baffles: to control the movement of the fluid.
To support the tubes
Gives stiffness to prevent sagging in tubes
Reduces flow induced vibrations
Directs flow in desired path
Nozzles: serves as In and out route of the exchanger. short pipe tube at the end of
the shell, used to direct or channel the flow of inlet & outlet fluids.
Shell:protective casing, a hard casing or covering that protects or House the tube
bundle. It also serves as a container for the shell side fluid.
Tie rod: braces the baffles, thus keeping the entire bundle in place.
Tube sheet: Tubes are welded to the tube sheet. It is also used for supporting the
tubes.
Tubes: conductible medium through which one of the fluid is channeled.
Bonnet cover: protective cover or protective cap
Partition plate: Allows proper routing of the fluid
 -Why do we need Heat exchanger ?

We need heat exchanger in order to bring the heat level in

the process fluids to a desired temperature.(to control the
temp. of process fluid)
AIR COOLED EXCHANGER
160`c EXAMPLES
CIRCULATING WATER SYSTEM FOR MELT CUTTER
Cycloaxane

3-EM-101

cutter
34`C

3-E-603
34.4`c
70`c

Melt
160`c-34`c=126`c
PURIFIER
70`c-34.4`c =35.6`c PLATE HEAT EXCHANGER

154+32.2=186.2 2-E-2301
186.2- 52.1=104`c

Ethylene feed
-Ethylene LP steam inlet
52.1`C

-cycloaxane 54/55`c
54/55`c
-butene 1 154`c 104`c
3-E-303 2-E-2301
Head tank Reactor feed heater/cooler
2-R-2301
3-E-304 56/57`c
56/57`c
32.2`c
Tube & shell exchanger c.w. inlet
Required Dt in the reactor is within the range of 2-3

Sheet 4
REACTOR:3-M-301
Waste heat/ Cyclohexane recovery
3-E-903
 Kettle Type Reboiler,Distinctive
features
 Used for boiling liquids.
 Enlarged shell Provides more space for
vapour/liquid seperation
 Horizoontal only
 Tube bundle is removable
 Costly shell
-The hot fluid goes through the tube while the
cooling water takes part of the shell living part
of the shell empty for vapor /steam generation
VAPORIZER,2-E-2401
 Straight tube(fixed tube sheet)Design(distinctive
features)
– The Simplest in design.
– Without packed or gasketed joints on the shell side.
– The tube sheet is welded to the shell and the heads are
bolted to the tube sheet.
Merits:
– Less costly than removable bundle designs
– Allows for single and multiple tube passes for proper velocity;
Limitations:
– Shell side can be cleaned only by chemical methods;
– No provision to allow for differential thermal expansion-- must
use an expansion joint.
Applications:
 Oil coolers, liquid/liquid exchangers, vapor condensers,
reboilers, gas coolers,
 More viscous and warmer fluids generally flow through
the shell;
 Corrosive or high-fouling fluids should flow inside the
tubes.
Condenser. 3-E-901 / 3-E-902
Floating Head Exchanger
 FLOATING HEAD DESIGN(distintives features)
Merits

– Floating head design allows for differential thermal expansion

between the shell and the tube bundle
– Shell circuit can be inspected and steam cleaned.
– Provides multi pass tube circuit arrangement.

Limitations

– Shell-cover, split-ring and floating head cover must be removed
to inspect the tube bundle. That results in higher maintenance
cost than with the pull-through bundle;
– More costly than fixed tube sheet or U-tube designs.
Applications:
– Chemical processing of toxic fluids;
– Special intercoolers and after coolers;
– General industrial uses.
Cooler / Heater 3-E-304 & 3-E-303
U-tube Design
 U-TUBE DESIGN
(DISTINCTIVE FEATURES)
Merits-
-Especially good for severe performance requirements with maximum thermal
expansion capability.
-Because each tube can expand and contract independently, the design works
well with large temperature differentials.

– U-tube design allows for maximum differential thermal expansion

between the shell and the tube bundle--for individual tubes too.
– One tube sheet only is required.
– Withstands thermal expansion applications.
– Bundle can be removed from one end for cleaning or replacement.
– Less costly than floating head or packed floating head designs
limitations
 Because of the 180º bend, U-tubes can be cleaned only by chemical
means.
 U-tubes are difficult to replace(retube).
 Not suitable for dirty fluid as choke will result at 180` bend end
 Tube side bends can lead to errosions
 Applications:
– Oil, chemical and water heating applications;
 Excellent in steam to liquid applications.
Requirements for HX Design
Design consideration for HX
Identify application- temp, heat load, mass flow rate ,etc
Decide on construction type / flow pathern-single/ multi pass
Evaluate heat transfer coefficient on hot / cold side
Determine dimension
Engineering Materials
TEMA Exchanger Nomenclature
 Plate
exchanger
“Plate exchanger”
normally refers to
as gasketted plate-
and-frame
exchanger
•Plates hung vertically and clamped in a press or frame.
•Gaskets direct the streams between alternate plates and prevent
external leakage
•Plates made of stainless steel or higher quality material
•Plates corrugated to give points of support and increase heat transfer
 -Low system pressure drop

-Large Surface area,hence,more heat transfer effet

1. Significant advantages whenever there are clean fluids

-Unsuitable for solid suspensions of larger than 2mm diameter

-Good for low pressure systems as plates can not withstand higher pressures
 Air-cooled exchanger
 Air blown across finned tubes (forced
draught type)
 Can suck air across (induced draught)
 ACHE bundle

Eg:3-E-922,101,905
 Air Cooled Heat Exchangers
 Uses air cooling forced or induced
 At times a combination with water cooling too (
eg. Automotive radiators, motor fins )
 Withstand temperatures exceeding 300 deg F
 Design is usually carried out by specialists who
will optimize such criteria as :
 Capital versus running costs.
 Induced versus forced draught fans (induced =
better air distribution and hailstone protection;
forced = less power and easier maintenance).
 Type and spacing of fins
 Number of tube rows.
 Noise, type and design of fans
 Air Cooled Heat Exchangers
MERITS
 Eliminates problems associated with cooling water.
-Corrosion
-Disposal-none
-Scaling/Fouling
-No exchanger cleaning
-Low installed operating cost
-Can economically cool Fluids to as low as 45°C.
 LIMITATIONS
 Higher initial heat exchanger cost as compared to water cooled
equipment.
 Noise levels from 60 to 90 dBa.
 Air side subject to fouling in dirty ambient conditions.
 Larger in size than comparable water cooled equipment.
 Not suitable for cooling dirty fluids
Reasons for poor performance of HX
•There are a wide range of heat exchanger problems which may cause
poor performance.

Some of the most common heat exchanger problems for many process
plants include the following;

-Vibration issues
-Exchanger leakage
-Air binding due to lack of suitable vents
-Fouling.
-Water quality
-Flow distribution
-velocity
-MOC
-Excessive clearances between the baffles and shell due to corrosion
-Operating conditions differing from design conditions

*Higher velocities increase erosion(gradual wearing away) /pressure drop

•Lower velocities increase deposition of salts and results in scale
formation.
•Scale formation reduces heat transfer.
 MAINTENANCE
Heat exchanger fouling (clogged with dirt,slurries)
is a major reason for exchanger maintenance.

Over time, as material builds up on the heat transfer surfaces of a typical heat
exchanger, an insulating layer is formed that reduces the heat transfer rate and
increases pressure drop through the exchanger.

Eventually, the heat exchanger must be cleaned to restore the heat transfer
rates and pressure drops required by the process.

Fouling refers to any change in the solid boundary separating two heat transfer
fluids, whether by dirt accumulation or other means, which results in a
decrease in the rate of heat transfer occurring across that boundary.
STEPS INVOLVE IN CARRYING OUT CLEANING SERVICES OF HEAT EXCHANGER

Safety measures
• Ensure to get work permit from process.
• Ensure isolation of process/ cooling water lines.
• Ensure certification of scaffolding by safety incharge before use.
• Ensure to put on proper PPE before carring out the job.

SEQUENCE OF ACTIVITIES
• Blinding of Inlet & OUTlet nozzles.
• Debolting of the end covers.
•Dropping of the covers / inlet & outlet spool pieces by means of chain block or crane.
• Inspection.
• Cleaning (hydrojectting,drilling,pocking, manual Rodding,hydroblasting).
• Drying of the tubes with N2 (Nitrogen).
• Inspection.
• Box-up of the covers and the spool pieces.
• Hydro-test / pneumatic test of the shell side & tube side.
• Inspection.
• Deblinding(removal of the blinds)
• Final box-up
• House keeping

TOOLS / MACHINES / MATERIALS

•Spanners / Hammer / Shackles / Scrapper/ Hand wire brush/ steel rod
• Sling wire/ Belt
• Chain block / Folk lift
• Drilling Machine / Hydrojectting machine / Crane
• Scaffolding
• Gaskets / Blind / Plug
 MAINTENANCE OF HEAT
EXCHANGERS
► Tube Bundle Removal and Handling: To avoid
possible damage during removal of a tube bundle
from a shell, a pulling device should be attached to
eyebolts screwed into the tubesheet. If the tubesheet
does not have taped holes for eyebolts, steel rods or
cables inserted through tubes and attached to
bearing plates may be used. The bundle should be
supported on the tube baffles, supports or tubesheets
to prevent damage to the tubes. Gasket and packing
contact surfaces should be protected.
 MAINTENANCE OF HEAT
EXCHANGERS
► Cleaning Tube Bundles:
 Cleaning Methods: The heat transfer surfaces of
heat exchangers should be kept reasonably clean to
assure satisfactory performance. Convenient means
for cleaning should be made available.
Heat exchangers may be cleaned by either chemical
or mechanical methods. The method selected
depends on the type of deposit and the facilities
available in the plant. Following are several cleaning
procedures that may be considered:
 MAINTENANCE OF HEAT
EXCHANGERS
 Circulating hot wash oil or light distillate through
tubes or shell at high velocity may effectively remove
sludge or similar soft deposits.
 Some salt deposits may be washed out by circulating
hot fresh water.
 Commercial cleaning compounds are available for
removing sludge or scale provided hot wash oil or
water is not available or does not give satisfactory
results.
 MAINTENANCE OF HEAT
EXCHANGERS
 High pressure water jet cleaning.
 Scrapers, rotating wire brushes, and other mechanical
means for removing hard scale, coke, or other
deposits.
 Employ services of a qualified Agency that provides
cleaning services. These agencies will check the
nature of the deposits to be removed, furnish proper
solvents and / or acid solutions containing inhibitors,
and provide equipment and personnel for a complete
cleaning job.
 MAINTENANCE OF HEAT EXCHANGERS
Cleaning Precautions:
 Tubes should not be cleaned by blowing steam through individual
tubes since this will heat up the tubes and may result in severe
expansion strain, deformation of the tubes, or loosening of the
tube-to-tubesheet joint.

Pneumatic Test:
When liquid cannot be tolerated as a test medium, the exchanger may
be given a pneumatic test in accordance with the code. It must be recognized
that air or gas is hazardous when used as a pressure testing medium. The
pneumatic test pressure at room temperature shall be in accordance with the
code.
 Standard Test: The exchanger shall be hydrostatically
tested with water. The test pressure shall be held for at
least 30 minutes. The shell side and tube side are to be
tested separately in such a manner that leaks at tube joints
can be detected from at least one side.
 MAINTENANCE OF HEAT EXCHANGERS
Gasket Replacement:
Gaskets and gasket seating surfaces, should be thoroughly cleaned
and should be free of scratches and other defects. Gaskets should
be properly positioned before attempting to retighten bolts. It is
recommended that when a heat exchanger is dismantled for any
cause, it be reassembled with new gaskets. This will tend to
prevent future leaks and / or damage to the gasket seating
surfaces of the heat exchanger.
Composition gaskets become dried out and brittle so that they do not
always provide an effective seal when reused. Metal or metal jacketed
gaskets, when compressed initially, flow to match their contact surfaces.
In doing so, they are work hardened and, if reused, may provide an
imperfect seal or result in deformation and damage to the gasket contact
surfaces of the exchanger.
Tube Expansion:
A suitable tube expander should be used to tighten a leaking tube
joint. Care should be taken to ensure that tubes are not over
expanded.
 MAINTENANCE OF HEAT
EXCHANGERS
 Gasket Replacement:
Bolted joints and flanges are designed for use with the
particular type of gasket specified. Substitution of a
gasket of different construction or improper dimensions
may result in leakage and damage to gasket surfaces.
Therefore, any gasket substitutions should be of
compatible design.
 Any leakage at a gasketted joint should be rectified and
not permitted to persist as it may result in damage to the
gasket surfaces.
 Before cleaning

Observations after cover of the exchanger is opened

for cleaning. As can be seen in the Pixs, polymer is The tube bundle as could be seen partly is fouled with brownish
observed on tube sheets, tubes ID, channel head, muddy sludge as shown
partition plates and on end covers

After cleaning
EA-3216 S- CM Condenser (New)
Before Hydrojetting

After Hydrojetting
•Hydrojectting with high pressure hydrojecting machine , to remove debris/dirt from the heat transfer
surface.
•Drying of the tubes with nitrogen to get rid of water in the tubes in order to avoid corrosion of the
tubes / contermination of product.
Pressure (Pneumatic) test on the tube side using:
1. Plant nitrogen, introduced into the tube side to a pressure of
6kg/cm2 and allowed to stand at that pressure for 1 or 2 hrs. chec
for leakage by soap solution or drop in pressure by observing the
PG.

2. Ethylene gas could be added to raise Nitrogen pressure of

6kg/cm2 to 29kg/cm2. Allowe to remain at that pressure for 30-
60minutes. Observed pressure drop.

Shell side hydro test at 20.55kg/cm2G allow for

about 2hrs, observe:
•Tubes integrity
•PG
•etc
MAINTENANCE OF HEAT
EXCHANGERS
 Recommended Bolt
Tightening Procedure

Recommended Bolt Tightening Procedure:

It is important that all bolted joints be tightened uniformly and in a diametrically
staggered pattern, except for special high pressure closures when the instructions of the
manufacturer should be followed.
THANKS , for YOUR concentration