DEFINITION - HEAT EXCHANGER

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 never mix.
OR

Heat exchanger is defined as a device used to

transfer heat from a fluids on one side of a barrier to

another fluid, flowing on the other side of the barrier.

TYPES OF SHELL AND TUBE

HEAT EXCHANGER
SHELL AND TUBE
TYPE

HEAT EXCHANGER

FIXED TUBESHEET

FLOATING
TUBESHEET

U BUNDLE
WITH SINGLE
TUBE SHEET

FIXED TUBESHEET

SUMMARY
Two tube sheets with tube bundle assembled in between, are

fixed to both ends of the shell.

Tube sheets are either directly welded to shell or bolted to

flanges which are welded to shell ends.

Differential expansion if any, will develop stresses in tubes &

shell material.

To take care of differential expansion, shell may require

expansion bellows.

FLOATING TUBESHEET

SUMMARY
One tubesheet is fixed to one end of the shell.
Other tubesheet is floating within the shell with

a floating head cover.

This facilitates tube & shell to expand independently

without inducing any stresses due to differential expansion.

No expansion bellow is required on the shell to take

care of differential expansion.

U BUNDLE WITH SINGLE

TUBESHEET

U TUBE BUNDLE, KETTLE

TYPE EXCHANGER

SUMMARY
U bent tube bundle assembled on one tubesheet.
Assembled tube bundle is inserted into the shell.
Tube sheet is bolted to shell flange.
U tubes can expand freely inside the shell.
No stresses due to differential expansion.
No expansion bellow is required on shell to take

care of differential expansion.

STANDARD CLASSIFICATION
AS PER TEMA CODE
TEMA Class R for severe requirements of

petroleum / petroleum related application

TEMA Class C for moderate requirements of

Commercial and General process application

TEMA Class B for Chemical process service

MAJOR COMPONENTS
SHELL
NOZZLES
CHANNEL
DEND
TUBESHEET
TUBES
BAFFLES
TIE RODS

FUNCTION OF BAFFLES
They guide the shell side flow in back & forth

as well as up & down direction, across the

tube field, increasing the velocity & the heat
transfer coefficient.
They support the tubes and hold them in
proper position during assembly & operation.
Prevent vibration of the tubes caused by flow
induced eddies.

TYPES OF BAFFLES
Single Segmental Baffle Cuts
Multi - Segmental Baffle Cuts

Double Segment
Triple Segment
Disc & ring type

SINGLE SEGMENTAL BAFFLES

VERTICAL

HORIZONTAL

ROTATED

MULTI - SEGMENTAL BAFFLE

DOUBLE SEGMENTAL CUTS

MULTI - SEGMENTAL BAFFLE

TRIPLE SEGMENTAL CUTS

DISC & RING TYPE BAFFLE

TUBE # TUBESHEET WELDING

Tube # tubesheet welding is defined as

process of joining tube to tubesheet in a heat

exchanger by welding.

VARIOUS TYPES OF TUBE #

TUBESHEET JOINTS
Strength Expanded Exp. Grooves in Tube
holes
Strength Expanded Without Exp. Grooves in
Tube holes
Seal Welded & Strength Expanded
(With or Without Expansion Grooves)
Strength Welded (Groove Weld Joint) & Light
Expanded

EXPANSION GROOVES

TUBE

TUBE SHEET

EXPANDED JOINT

EXPANDED & SEAL

WELDED JOINT

WELD GROOVE

STRENTH WELD.
MINIMUM 2
PASSES
TUBE

LIGHT EXPANDED AFTER WELDING

TUBE SHEET

T#TS Set up for Strength Weld

Strength Welded & Light

expanded

STRENGTH WELDED JOINT

WELDER QUALIFICATION PROCEDURE

SCOPE
This procedure covers

the requirements for

welding & testing of
tube # tubesheet joint
qualification

Reference documents
Article F-3 of ASME

SEC.IX(QW193,page-9).
ASME SEC.VIII
Customer specification

PREPARATION OF MOCK UP BLOCK

The tubesheet block shall be prepared on

a plate/forging of similar base material

(Thickness = or > 50 mm) for qualification
of welding procedure.
For qualification of welder the tubesheet

block shall be prepared a plate/forging of similar base

material (Thickness = or > 38 mm).
After machining, tube holes shall be drilled as per block

shown in fig-1.The hole size, pitch & weld edges shall

be identical to tubesheet of the equipment

WELDER TRAINING &

QUALIFICATION

1)
2)
3)
4)

At the beginning, welder shall be given practice on

mock up block to achieve acceptable bead finish
as mentioned below :
Control of welding arc to avoid melt through in tube
wall.
Proper arc manipulation
Staggering of restart points
Acceptable bead finishes without excessive
reinforcement

IMPORTANT NOTE
For procedure qualification 10 mock up welds

are to be produced within acceptable

standards, as mentioned in ASME SEC IX,
QW-193.1.
After adequate practice welders are allowed
to weld in a qualification block. The number of
joints in welder qualification block will be 5
nos as per ASME SEC IX, QW-193.2.

PRECAUTIONS BEFORE TUBE #

TUBESHEET WELDING
Uniform welding should be carried out while

welding tubesheet # shell .

Excessive bow will lead to difficulties while in
tube insertion stage.

Ovality should be maintained at minimum

level, to allow smooth baffle assembly.

OPERATIONAL SEQUENCES FOR

TUBE # TUBESHEET WELDING
Inside touchup
Baffle insertion
Tube insertion
Setup of tube # tubesheet
Welding of joints
Tube trimming
Leak test

INSIDE TOUCHUP
Inside touchup of entire shell is to be done to

avoid any restrictions during baffle insertion.

All inside seam should be checked for
minimum reinforcement.

BAFFLE INSERTION
While drilling the baffles, the drill bit usually

gets deflected from the centre line of the

hole throughout entire stack.
Hence, it is advisable to install the baffles
in the direction of drilling with respect to
the tubing direction.
Baffles are inserted into the shell with the
help of fixture.

FIXTURE FOR BAFFLE INSERTION

TUBE INSERTION
Cleaning of tube & tube sheet is the most

primary requirement before tube insertion.

Utmost care is to be given for the cleaning
process according to the standard practices.
Tube insertion is done with the help of pilots
which provides ease in tube insertion.

STANDARD L&T PRACTICES

The tube holes and out side surface of tube

shall be cleaned thoroughly to remove any

oil, grease, rust, dust from surfaces.
Tube ends should be cleaned minimum upto

200 mm of length at both ends by wire

wheeling.

SETUP OF TUBE # TUBESHEET

Setup is to be done in accordance to the

projection mentioned in the drawing.

Projection rings are utilized to ensure the

projection of tubes with respect to tube sheet.

PREPARATORY ARRANGEMENT
BEFORE WELDING

After insertion of tubes in tube holes, the tube ends

shall be pulled outside for cleaning of tube OD. The
corresponding hole ID on opposite end shall be
cleaned (35mm, minimum). In a row, one tube shall
be pulled forward and adjoining tube shall be pushed
backward for cleaning of tube OD and hole ID
alternatively.

Availability of high purity argon cylinder duly cleared

by welding engg. For purity check, bead-on-plate
deposit shall be carried out. After grinding the bead
to remove the half thickness, PT check shall be
performed. Each tested and cleared cylinder shall
bear signature of welding engineer.

 Thoriated Tungsten (3.0 dia.)

High frequency unit in welding m/c is working.
Pre and post flow of shielding gas is properly

adjusted.
Welders are qualified to weld that particular joint and
cleared RT of joint on mock -up piece before start of
welding.
Gas cup with gas lenses.
Leakage of shielding gas in connections
Water cooling system and water circulation is in
order.
Joint shall be cleaned with acetone just before start
of tack welding

PRECAUTIONS WHILE WELDING

Follow the welding parameters as specified in WPS.

Welding to be performed with shortest possible arc.
Only vertical up progression is to the used.
Projection of tungsten electrode from gas cup shall
be kept max 6.0 mm.
Tungsten inclusion to the avoided. In case of any
doubt the point shall the dressed before proceeding
for further welding.
Arc initiation shall be using high frequency limit.
Restart point in a pass shall be kept at least 4mm
before the crater point of the bead. The restart of
successive passes shall be staggered w.r.t previous
passes.

During PT after root pass it shall be ensured that the

penetrant (dye) is not entering the un-welded joints.
If the dye has entered the in welded joints, the joint
shall be cleaned thoroughly by pulling the tubes
forward and backward.
Weld shape & size shall be controlled to meet the
requirement of visual inspection. For weld size
correct fillet gauge shall be used.
Only one welder shall the allowed to complete a
joint. Mix up in a joint shall be avoided.
Welding record of each T#TS joints shall be
maintained with data and welder stamp.
The argon cylinder shall be replaced when there is
positive pressure. ( 10 kg per sq.cm)

Filler wire shall be cleaned with emery paper

followed by acetone cleaning. After cleaning, it shall
be handled using cleaned cotton hand glove
While using inconel filler wire, the arc shall be kept
on CS tubes to avoid excessive melting of SS
cladding.
Joints shall be thoroughly cleaned after PT before
depositing next passes.
Oxidized ends of filler wire shall be cut before
reusing it.

WELDING DEFECTS

TUBE TRIMMING
Tube trimming is required to be done after

welding root pass of all tubes in one

tubesheet.
It is done to remove excessive tube length by
machining on job.
Supervisor should observe that minimum
tube length trimming ( < 10mm ) is required.

LEAK TEST
Air and soap solution leak test.
Helium leak test.
Kerosene leak test.
Hot oil test.
Halogen leak test.

USEFUL CALCULATIONS
Welder output.
Counterweight calculation.
Shell trimming.

WELDER OUTPUT
Calculate welder output for a job with 10000 nos of tube with

20mm dia per shift?

Assume that efficiency of average welder for tube # tubesheet

welding is 25mtr/12hrs.
Circumference of tube = 2*pie*r
= 2*3.14159*10
= 62.83mm
= 63mm approx.
Welder output/shift = Average efficiency/circumference
= 25*1000 / 63
= 397 passes (approx).
No of passes/tube = 2 passes / tube
Total nos of tube which could be welded/shift = 397/2
= 199 nos (approx)

COUNTER WEIGHT CLACULATION

Counter weight = x
X * RHS span = Weight of baffle * LHS span
X * 5 = 10*5
Hence, counterweight X = 10 ton

SHELL TRIMMING
Shell trimming for A-type weld configuration.
X = L-2P-T1-T2-B1-B2+S

SHELL TRIMMING
Shell trimming for B-type weld configuration
X = L-2P-T1-T2-B1-B2-2H-2R+S

ABBREVATIONS
X = Distance from the edge of tubesheet to

shell edge (actual).

T1 = Thickness of tierod tubesheet (actual).
T2 = Thickness of second tubesheet (actual).
P = Required tube projection
L = Length of tubes (actual)
H = Height of lip on second tubesheet
R = Root gap between tubesheet & shell
B1 = Bulge on tie rod tubesheet after welding
(actual)
B2 = Expected bulge on second tubesheet
S = Shrinkage of tubesheet