HEAT EXCHANGERSHEAT EXCHANGERS introduces the learner to the phenomenon of heat transfer as itis applied in modern refining techniques. In Section 1: Heat ‘Transfer, conduction and convection as methods of heat transfer are explained before the more practical matter of heat transfer in tubes is discussed. ‘Section 2: Heat Exchange Equipment first details the various parts of heat exchangers as well as their functions. It then describes the various types of shell and tube heat exchangers. Section 3: Exchanger Operation and Maintenance goes into startup and ‘shutdown procedures and deals with various problems of exchanger main- tenance. Itthen describes the flow and mechanisms of various heat exchange systems.INSTRUCTIONS This isa programed learning course. Programed learning gives information in a series of steps called frames. Each frame gives some information and asks ‘you to make use of it. t, cover the response column at the Here is how it works. right with a mask, Read this frame and use the information it gives to fill in the blank. A micrometer is an instrument ‘thousandths of an inch. jgned to measure in ‘A micrometer is a good tool for measuring very. differences in size. Move the mask down to uncover the word at the right of the frame. If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame, ‘The drawing of a micrometer provides information that will ‘help you fill in the next blanks. oBsect 70 BE MEASURED. anviL THINBLE SPINDLE ‘Seven major parts are shown in the drawing, but only the. ind the____contact the object to be measured. small anvil, spindle‘The next frame calls for a choice. Circle or underline the ap- propriate word. Of the two parts that contact the object, only the (anvilf spindle) moves. ‘A program is @ series of frames that work like the ones you hhave just done. Read the frame, Use the information to fill in the blanks or make 2 choice. Move the mask down and check the response column, Go on to the next frame, Remember to cover the response column with a mask before you begin each page. spindleHEAT EXCHANGERS ‘Section 1: Heat Transfer HEAT TRANSFER BY CONDUCTION, Exhibits 1 through 10 are printed in a special pull-out section in the center of this book. Please pull them out now so that you can Freer to them as they are mentioned in the text 1, Heat is a form of energy. Like other forms of eneray, heat can be from one place to another. 2. The process by which heat travels through a substance is called conduction, Thus, the material through which heat passes is called the 8. Suppose a container of hot water is placed next to a con- tainer holding an equal amount of cold water. I¥ the containers are touching, eventually the temperature ) of the cold water (increases / decreases ) 4. And, the temperature of the hot water '5. Heat has been conducted from the container of hot water to the container of cold water, When the water in the two containers reaches the same ‘temperature, heat transfer {stops still continues ) 6, In other words, conduction of heat continues until the heat 's evenly distributed throughout the substance. The final temperature is ( greater than / less than / an average of )the two beginning temperatures. 7. One thing that the rate at which heat is conducted through ‘@ conducting material depends on is the nature of the material ‘Some materials are better than others, moved, or transferred ‘conductor increases decreases an average of conductors8. Copper, for example, is a better conductor of heat than cast ion. {A stove made of solid copper conducts heat ( more rapidly // more slowly )than one made of cast iron. ‘8. Suppose equal amounts of heat are applied to a one-inch thick piece of steel and to a two-inch thick piece of steel It takes longer for heat to pass through the metal in exam- ple (A/B) 10. Suppose two steel rods are heated at one end. {takes longer for heat to pass from one end to the other of rod (A/B). more rapidly11, Look at this drawing of two sets of containers. 40° 140? a | h i eid ae a i Acne Fig.1 In Figure 1, the difference in temperature between con- tainer Aand container Bis ps 100° 12. In Figure 2, the difference in temperature is a 150° 18. Conduction takes place ata faster rate in Figure 2. ‘Therefore, the rate of conduction varies with the size of the temperature difference 14, A standard measure of the rate at which conduction takes place is called thermal conductivity. ‘Thermal conductivity takes into account whether the mate- rialisa— conductor, the {900d thickness and of the conductor, and the amount Jength of the temperature, Fonsi difference HEAT TRANSFER BY CONVECTION 16. This drawing represents a room containing a heat source in one comer. ‘The air which touches the heat source is heated by Lary conduction16 i 18 19. 20. a1 ‘As the air touching the heat source is heated, it expands ‘and becomes | lighter / heavier } than the.air in the rest of the room. Because itis lighter, the warm air (rises / falls). Cooler air from the floor level moves up and contacts the source 1100 becomes lightar from expansion and { rises / falls } ‘This process is repeated again and again and produces a circular flow pattern. ‘As the air flows around the room itcarries —___ with it ‘As warm and cold gir meet near the center of the room, the circular flow pattern is interrupted and turbulence ‘ccurs, 22 Warm air and cold air are mixed together, and heat. is transferred from the to the all. Convection is heat transfer from one point to another within a liquid or gas by the mixing of one portion with another. Heat is transferred from the heat source to the air by (conduction / convection } and from the warm air to the cold air by ( conduction / convection }. lighter rises heat rises heat ‘warm; cold conduction convectionHEAT TRANSFER THROUGH TUBES, 23, Ifthe temperature ofa fluid flowing inside a tube is differ- tent from the temperature of the atmosphere outside the tube, _______ flows through the tube wall heat 24. ‘The amount of heat that flows depends on the tempera- ture —__ between the fluid and the outside difference atmosphere. 25. Typically. fluids flow in tubes in two distinct ways, LAMINAR FLOW TURBULENT FLOW ‘There is a great deal of mixing in ( turbulent / laminar ) turbulent 26, The type of flow in which the fluid flows in smooth stream- lines is —tlow. laminar 27. As the fluid flows, the molecules of the fluid rub against ‘one another. The friction of the molecules against each other causes ‘a resistance to flow, which tends to ( speed up / slow down } flow. slow down28. This drawing shows fluid flowing near the wall of a tube, STATIC FILM MAINSTREAM ‘TUBE WALL ‘The fluid that is flowing closest to the tube wall (is /is not ) is not turbulent 29, The friction of the fluid closest to the tube wall causes this, fluid to flow ( quickly / slowly } slowly 30. This slow-flowing fluid acts as a static film covering the tube wall Heat travels through the tube wall by conduction, and, in order for the heat to reach the main stream, it must pass through the static film by aso, conduction 31. Ina turbulent stream, the fluid molecules mix to a great ‘extent. ‘As the mixing process continues, (many / few fluid mole= many cules come in contact with the static film. aadtfnen these fluid molecules come in contact with the Satin hey abe geo neat absorb 33, The molecules which have absorbed heat from the static film —-_____some of the heat to other molecules. transfer in the mainstream. 84. Heat is transferred to the molecules that come in contact, with the static film by ( conduction / convection } conduction 85, These molecules carry the heat to another part of the mainstream and transfer some of the heat to other mole- cules. This is heat transfer by convection 6. In turbulent flow, the transfer of heat from the static film ‘tothe mainstream is by eon sh op ‘conduction; convection 87. Fluid farther from the tube wall flows ( faster / slower }. faster 88, The fluid that is flowing fastest is (in the center / at the Inthe conter edges } of the mainstream.99. Fluid in laminar flow acts much as if it consisted of many, ‘thin-walled tubes ofthe fluid, oe inside the other. TUBE MAINSTREAM In order for the mainstream to absorb heat, the heat must be from layer to layer. ‘conducted, or transferred 40, A fluid can be expected to absorb heat at a faster rate in (Cturulent / laminar } flow. turbulent 41. In-comparison to metals, fluids are poor conductors. In comparison to the tube wall, the time it takes for heat to transfer through the static film is areater/ loss ) loss } 42, The thicker the static transfer time. Im, the ( greater / less } the heat less 49, Heat transfer time can be decreased by ( increasing / decreasing ) the thickness of the static film. decreasing 44, The thickness of the static film depends on the amount of turbulence, When turbulence is slight, the static film is thick. ‘As turbulence becomes greater, the static film becomes Lea thinner, oF less, 45, Heattransfertime through the static lm can be decreased by increasing the — — of the flu turbulence46. 47. 48, 49, 50. 5 52 Different fluids are flowing on both sides of a tube. OUTSIDE FLUID STATIC FILM TUBE WALL. STATIC FILM INSIDE FLUID STATIC FILM TUBE WALL. STATIC FILM OUTSIDE FLUID ‘The friction of the outside fluid on the tube wall causes the fluid closest to the wall to flow ( quickly / slowly). ‘Thé fluid closest to the tube wall becomes a file ‘Assume that the fluid outside the tube is hotter than the fluid inside the tube. Heat flows from (inside to outside / outside to inside ) of the tube, In order for the heat to reach the tube wall, it must pass, from the mainstream through the static ‘The greater the turbulence outside the tube, the {thicker / thinner } the static film, ‘Tho greater the turbulence outside the tube, the { more / fewer ) molecules come in contact with the static film. ‘The factors affecting heat flow inside and outside tubes are ( similar / different }. slowly static outside toinside film thinner more similar53, This drawing illustrates flow inside and outside a tube. Boies SOE Nome oe ] FLUID INSIDE TUBE as wat 1. INSIDE FLUID FILM INSIDE FOULING MATERIAL FLUID OUTSIDE TUBE OUTSIDE FOULING MATERIAL OUTSIDE FLUID FILIA 71, the temperature inside the tube, is ( higher than higher than lower than } Ts, the temperature outside the tube. 4, The line segment between Ts and Ts,represents the temp- frature drop across the inside fluid film 55. Ts to Ts's the temperature drop across the inside scale or fouling material. Compared to the drop from Ts to Ts, the drop from Tsto Ts is (steeper /less steep } steeper 56. T.to Tsrepresents the temperature drop through the tube wall and Tso Te represents the drop through the outside fouling material The temperature drop through the tube wall is close to zero57 58. ‘The temperature drop is greater ( through the tube wall / through the inside and outside static films ) The shape of the outside temperature curve is similarto / different from } the shape of the inside temperature curve Parallel Flow ~Countertlow 50. 60. et 62, 63, Heat flows from one fluid to another if there isa in temperature between the two fluids, ‘Assume that fluid is flowing along both the inside and the ‘outside ofa tube and that both streams of fluid are flowing in the same direction and that the fluid inside is hotter than the fluid outside Heat is transterrod from the _______ fluid to the ‘ld. The temperature of the hotter fluid ( increases / decreases ). ‘As heat is transferred to the colder fluid, its temperature Allthe fluid represented here is flowing in the same direc- tion. 64 65 The temperature of the inside (hotter) fluid is greatest at point (A/B/C), The temperature of the inside flu (AB/C). is lowest at point The temperature of the outside (colder) fluid Is lowest at point (A/B/C), 10 through the inside and static films similar to difference Inside outside decreases increases66. The temperature of the outside fluid is highest at point (A/B/C), c 67. This graph shows the temperature of the two fluids in relation to the length of the tube. PARALLEL FLOW Il I | | I I INSIDE FLUID | | > t ‘TEMPERATURE ! 1 1 1 I I I POINT A POINT s POINTC The difference in temperature is greatest at point ( A / A B/C). 68. The heat transfer rate ( depends / does not depend } on depends the temperature difference 69. The heat transfer rate is greatest at point( A / B/C). A 70. At point C, there (is / is no } temperature difference. sno 71. At point C, heat (is / is not) transferred. isnot 72. In parallel flow, when both fluids flow in the same direc tion, the hot fluid { can / cannot } be cooled below the cannot highest temperature of the cooler fluid. 78. The fluids are flowing countercurrently. In this kind of flow the fluids are flowing in ( the same direction / opposite directions } ‘opposite directions "74. 75. 76. 77 73, 79, 80, ‘Suppose that two fluids are in countertlow inside and out- side a tube, and the hotter fluid is inside. The temperature of the hotter inside fluid is greatest at (A/B7C) A ‘The temperature of the inside fluid decreases in the direc- tion (Ato C/Cto A). Atoc The outside colder fluid is coolest at ( A/B/C) s The outside fluid is hottest at (A/B/C), A This graph shows the temperature in relation to the length of the tube 1 y Lsioerum | \ 2 1 | arb ! ‘TEMPERATURE te | | oursipe Fup | eset | 1 I ) 1 I I I | | POINT A point s point ¢ In counterflow, the temperature difference along the tube is ( more constant / tess constant } than the temperature more constant difference in parallel flow. The heat transfer rate in counterflow varies ( consider ably / little over the length of the tube. litte Notice the area on the graph that is represented with a double arrow, Counterflow ( permits / prevents } cooling a fluid to a permits temperature lower than the highest temperature of the ‘cooling fluid. 12Section 2: Heat Exchanger Equipment Introduction 81. A.simple heat exchanger is a set of steel tubes enclosed in tank HoT OIL, The tank represents the shell of the exchanger and, in this case, is filled with 182. Heat is transferred from the hot oil flowing through the tubes to the cool water around the tubes. The conductor of the heat is the — wall 83. The shell-side of an exchanger is the area inside the shell and outside the tubes. ‘The tube-side of an exchanger isthe area the tubes, ‘84. Inthe example shown, the shell-side fluid is land the tube-side fluid is 13 water tube inside water oil85. This drawing shows the construction of a typical shell and tube exchanger. The tubes are anchored between two tubesheets ‘86, The combination of tubes and tubesheets is called the tube — bundle 187. This drawing shows the fluid flow path through a shell and tube exchanger ‘TUBESIDE INLET SHELL SIDE INLET HOTOLL ‘COOL WATER ‘TUBESIDE OUTLET ‘ ‘COOLED OIL SHELL SIDE OUTLET WARM WATER Hot oil flows into the tube-side inlet, through the tubes, and out through the "outlet tube-side 88. Cool water fiows into the shell-side inlet, around the and out through the shell-side outlet tubes £89. In this example, heat is transferred from the ( tube-side / shellside ) fluid tothe tid tube-side; shell-side‘TUBE BUNDLE 90. The greater the surface area of a conductor, the { more / less } quickly heat is conducted, 91. A bundle of small tubes has ( more / less } surface area than a single large tube. 92. Shell and tube exchangers use a bundle of small tubes, rather than a single large tube ‘This ( increases / decreases | the area for heat transfer. 93. Exchanger tubes can be either plain or finned, As these drawings show. fins are either or the tubes. 94. Fins add to / subtract from ) the tube surface area. 95. Thus,they_______ the rate of heat transfer. 96, Itacorrosive fuid passes through either side of an exchanger, something usually must be done to prevent 97. Sometimes the tubes can be made of @ metal which is not easily Reter to Exhibit 1 for frames 98-100. 98. The outside diameter (0. D.) ranges from 1/ inches. ich to 99. Inpractice, the most common tube O.’'sare the 1/2-inch, the 3/4-inch, and the one-inch. ‘As the chart shows, tubes with 0.D.'s at the extremes of the range, either high or low, are usually produced in (greater / fewer } varieties of gauges than the more com- mon sizes. more Increases inside outside add to increase corroded 24/2 fewer100, So, tubing with a 2-1/2 inch O.D. is usually produced in only one. 101. Exchangers are usually produced in standard lengths of 8,10, 12, 16, and 20 feet. Sixteen and 20 feet are the most ‘common lengths. ‘The particular application usually determines the —_ of an exchanger. 102. That is, exchanger design is determined by cost and the particular operating 103. As the length of an exchanger increases, its cost genor- ally (increases / decreases }. 4104. One of the basic considerations in exchanger design is to ‘meet operating requirements while minimizing ——__ TUBESHEETS 105. The tube bundle is made by fastening the tube ends into ‘openings in the tubesheet ‘TOBE SHEET Because the tubes cannot move in the tubesheets, the tubesheets and tubes forma solid / flexible } unt, 16 gauge, or thickness length conditions, or applications Increases cost solid108, In some exchangers, the tube and tubesheets are fixed to the shell Therefore, they ( are free to move / are prevented from are prevented moving }, from moving 107. Heat causes metal to expand / contract } expand 108. Whon the tubes expand because of heat, stress is placed fon the tubes and tubesheet. ‘Atube can come loose, allowing fluid to leak between the tube wall and the opening inthe es tubesheet 109. This results in the contamination of one fluid by another. ‘To guard against this, a double tubesheet can be used in cases where 2 absolutely cannot be leak tolerated110. Here is a design which can help reduce the possibilty of leaks at the tubesheet, DousLe TOsESHEET This design provides for a_______ between the space tubesheets, 111. Ifaleak occurs, fluid passes into this space. Since the space between the tubesheets is open. fluid is allowed to ( drain from / collect in } the exchanger. drain from ‘TUBE JOINTS 112. The tube joint is the connection between the tube and the tubesheet. The better the fit at the tube joint, the eee less the possibility at there is leakage.119. Tube joints are usually either rolled press fit or welded, WELDED ROLLED PRESS FIT (EXAGGERATED) Some metals cannot be welded, so tubes of these metals are rolled 114, Rolled joints usually make a very good seal, and they can be used in reasonably high pressure service. up to about 2,000 psi However, in special cases or severe service, welded tube joints are usually used. 118. An exchanger Is likely to be more expensive if the tube Joints are ( rolled / welded } welded TUBESHEET LAYOUT 118. Exchanger tubes can be installed in a variety of patterns, TRIANGULAR INLINE TRIANGULAR a ee IN-LINE SQUARE DIAMOND SQUARE te tee When the tubes are arranged in parallel rows, vertically. and horizontally, the pitch is called ——-_____ indine piteh.117, 118 119. 120, 121 122 123, 124, 125, In-line square pitch offers the { most / least) resistance to shell-side flow through an exchanger. ‘The greater the resistance to flow, the greater the result- ing pressure drop. For this reason, in-line square pitch is particularly efficient when conditions require a ( high / low } pressure drop. Staggering the tubes, as in the three other main types of pitch, allows ( more / fewer tubes in a given area than the ‘even spacing in square pitch does, A disadvantage of square pitch is the relatively number of tubes in a given area. Compare the number of tubes in a given area in square pitch and triangular pitch. SQUARE PITCH _ | TRIANGULAR PITCH ‘Shell | Number of Number of Passes. unohes)| 1 | 2 | + | 1 | 2] 4 20 | 241 | 296 | 224 | 269 | 260] 250 22 | 300} 280| 280 | 337 | 930] a14 24 | 360} 350 936 | 421 | 404 | 380 26 | 424 | 42 | 402 | 499| 476 460 28 | 402 | 483 | 480 | 579| se2| saz 30 | s80| 565 | 566 | 668 | 648 | 636 32 | 685 | 648 | 644 | 766 | 744 | 732 34 | 756 | 758 | 720 | 870| 850] 234 36 | 53 | sas | 832 | 86 | 978| 942 38 | 973 | 950 | 938 | 1108 | 1100 | 1060 40 |1085 | 1064 | 1052 | 1236 | 1228 | 1200, 42__|1201 | 1176 | 1162 | 1367 | 1350 | 1322 Ina 42-inch, double-pass exchanger. there are tubes in a square pitch arrangement and ____ tubes. ina triangular pitch arrangement, ‘The more tubes there are ina givenarea, the the heat transfer rate, Since the square pitch arrangement results in the lowest umber of tubes in a given area, it also results in the heat transfer rate, ‘When the pitch s triangular, the pressure drop is( higher / lower than when the pitch is square. But, the heat transferrate is greater when pitch is 20 least more low, or small 1.176 1,350 higher, or greater lowest higher triangular128. For agiven set of operating conditions the choice of pitch arrangements depends upon what pressure dropis needed in relation to the ‘transfer rate desired. BAFFLES AND TYPES OF BAFFLES 127, 128. 129, 190. ‘The longer the tubes in an exchanger are, the ( heavier / lighter } they are ‘The heavier they are, the the chance that they will sag, Baffles support the weight of the tubes, ‘Since they support the weight, baffies help to the sires on the tubing and tubesheet In both laminar and turbulent flow, a layer of fluid sur- rounds each tube, acting as an insulator. This layer of fluid acts to ( increase / decrease } the rate ‘of heat transfer. a heat heavier ‘greater decrease, or relieve decrease11. The thicker the insulating layer, the decreases heat transfer. it more 192. The insulating layer is likely to be thicker when flow is (laminar / turbulent j laminar 193. In addition to supporting the tubes, baffles break up flow, decreasing the layer of insulating laminar fluid. ‘Segmental Battles 194. segmental baffie isa circle from which either a vertical Cr horizontal portion has been cut In this case, the batties are ( vertically cut / horizontally vertically cut cut ) segmental battles 195. Segmental battles are positioned so that the cut-out areas (allface in the same cirection / face in alternate directions) face in alternate directions 196. Alternating the baffles causes flow to the cross, or pass tubes a number of times. 187. It also provides better _____ for the tubes. support188. In addition to the portion cut from the side or top of a seg- ‘mental baffle, a portion is often removed from the bottom, HORIZONTAL VERTICAL Removing this portion ( allows / prevents } some contin- allows ‘uous fluid flow along the bottom ofthe exchanger 199, Whether the batfie is cut vertically or horizontally depends on the type of fluid and on the operation HORIZONTAL, The baffle most likely to catch suspended materials is the (vertical / horizontal} battle. horizontal 23.140. But, suppose horizontal baffles were used in a condenser, GAS INLET, CONDENSED FLUID OUTLET Condensed fluid builds up behind baifies A and C, thus a — flow. restricting 4141. Drainage from the condenser is prevented and the effi- ciency of the exchanger is a decreased Disc and Doughnut Battles 142, The pattern of flow through disc and doughnut baffles is relatively uniform But, if the fluids are not clean, sediment builds up behind the { dise / doughnut } doughnut,143, Since the cutout area of the baffle is in the center, the low of condensed fluidsalona the bottom of the exchanger, can also be restricted 144, For these reasons, disc and doughnut baffles are used (‘more / less often than segmental baffles. less Impingement Battles 145. At high inletluid velocities, the fluid can seriously erode the tubes as it strikes them. If the inlet fluid contains suspended solid particles, the problem is (more / less ) severe more 146. Impingement baffles are sometimes placed at inlet flow areasto the shell-side. NOPLATE BAFFLE PLATE BAFFLE VERTICAL CUTS PLATE BAFFLE ee HORIZONTAL CUTS {As this comparative illustration shows, the impingement baffle helps to ( spread out / contain } fluid flow. ‘spread out 147, An impingement battle directs the flow ( toward the sides of the exchanger / toward the tubes } toward the sides of the ‘exchanger 148, The baffle effectively reduces the _____of the erosion tubes. 25149, Besides reducing erosion, spreading the fluid insures that the fluid contacts all the tubes. ‘And increasing fluid-tube contact _____ the increases heat transfer rate, Longitudinal Battles 180. Longitudinal baffles are sometimes used to spit shell-side flow into two or more passes. ‘Asthe drawing shows, the longitudinal baffle (is somewhat shorter than / extends the full length of } the exchanger. is somewhat shorter than 161. This allows for the return, or double pass, through the ‘exchanger, Three longitudinal baffles would provide for ___ four passes through the exchanger. 26