In the name of ALLAH,

the most Gracious, the most Merciful.

August 26
th
2010
INTRODUCTION TO
HEAT EXCHANGERS
NORMS
Please Switch your Mobiles to SILENT Mode
Pin Drop Silence is required till end of Lecture
Smoking is strictly Prohibited in Lecture Room
Questions only in Q/A Session

OBJECTIVES
State the principle of Heat Transfer
How a tube and shell type heat exchanger works
How a plate type heat exchanger works
Identify the major parts of heat exchangers
On completion of this lecture, the attendees shall clearly
understand the function and identify the basic
components of Heat Exchangers.
They shall also be able to correctly:
BASICS
HEAT : a form of energy associated with the
movement of molecules in a body.

Modes of Heat transfer
Conduction Convection Radiation
COLD
HOT
HEAT
BASIC PHILOSPHY
Thermodynamically: Heat always flows from hotter medium to colder
HOT FLUID
COLD FLUID
BASIC PHILOSPHY
Hotter Fluid
Colder Fluid
POINTS OF DISCUSSION
INTRODUCTION
CONSTRUCTION
TYPES
TYPES ACCORDING TO TEMA
MAINTENANCE
PLATE HEAT EXCHANGERS
WHAT IS HEAT EXCHANGER
The equipment or arrangement made to transfer
heat between hot and cold streams through a
combined conduction-convection mechanism is
called Heat Exchanger.
DEFINITION
Names as Per Application
Coolers
Burners
Heaters
Evaporators
Condensers
Cooling Towers
Chillers
Air Conditioners
Boilers
Re-boilers
Steam Generators
Radiators
Etc .

HEAT EXCHANGER - CLASSIFICATION
A - TRANSFER PROCESS
B - FLOW ARRANGEMENT
C - GEOMETRY OF CONSTRUCTION
Direct Contact
Indirect Contact
Parallel Flow
Counter Flow
Cross Flow
Tubular
Plate Type
Extended Surface
CLASSIFICATION BASED ON GEOMTRY
HE
PLATE TYPE.
TUBULAR.
EXTENDED SURFACE.
TUBE FINNED
PLATE FINNED
DOUBLE PIPE
SHELL & TUBE
SPIRAL TUBE
FIXED TUBE
FLOATING HEAD
U - TUBE
GASKETED
WELDED
TUBULAR HEAT EXCHANGER
PLATE TYPE HEAT EXCHANGER
FINNED HEAT EXCHANGER
FINNED HEAT EXCHANGER
BASIC COMPONENTS - EXTERNAL FEATURES
Front Channel Head
Shell
Rear Channel Head
Nozzle: Tube Side Flow Nozzle: Shell Side Flow
Bellow
(Expansion Joint)
Gasket
Vent
Drain
BASIC COMPONENTS - INTERNAL FEATURES
Baffle Plates
Sliding Rod
Dummy Tube
Front Tube Sheet Rear Tube Sheet
Tubes
Impingement Plates
Tie Rods
&
Spacer
Partition Plate
PARTITION PLATES
BOX TYPE PARTITION PLATE
VAPOR BELT
USED TO DISTRIBUTE FLUID EVENLY ROUND TUBE BUNDLE
CLASIFICATION - TUBULAR HEAT EXCHANGER
SHELL & TUBE
FIXED TUBE
FLOATING HEAD
U - TUBE
FIXED TUBE SHEET
Shell
Shell Welded with
Tubesheet
Tubesheet
- Tubesheet Welded with the Shell
- Tube-Bundle is not Removable
- Tubes Secured at Both Ends (with 02 Tubesheet)
- Channel Cover may be Removable
FIXED TUBE SHEET
- Non-fouling Fluids at Shell Side
- Fluids with no Permissible Leakage
APPLICATIONS
- Low Cost
- Maximum Protection Against Shell side Leakage
ADVANTAGES
- Shell Side is not Accessible for Cleaning or Inspection
- Expansion Joint is Required to Relive Thermal Stresses
DISADVANTAGES
FLOATING-HEAD TUBE SHEET
Shell
Fixed Tubesheet
Floating Tubesheet
Gasket
Gland Packing
O Ring
Lantern Ring

- One Tubesheet is Free to Move
- Tubes Secured at Both Ends (with 02 Tubesheet)
- Tube-Bundle is Removable
- Fouling Fluids at Both Side
- Large Temperature Difference b/w Shell & Tube Side Fluids
APPLICATIONS
- Easy Cleaning and Inspection
- No thermal Stress Generation
ADVANTAGES
- High Cost
- Cannot be Used where Leakage cannot be Tolerated
DISADVANTAGES
FLOATING-HEAD TUBE SHEET
U-TUBE BUNDLE
Shell
Tubesheet
Gasket
- Tube-Bundle is Removable
- Tubes Secured at One Ends (with 01 Tubesheet)
- Fouling Fluids at Shell Side
- Large Temperature Difference b/w Shell & Tube Side Fluids
APPLICATIONS
- Less Expensive
- No thermal Stress Generation
ADVANTAGES
- Difficult Tube Cleaning
- Tube Replacement is Difficult (Except Outer Tubes)
DISADVANTAGES
U-TUBE BUNDLE
- Tube-Bundle can be Easily Removable for Cleaning or Inspection
KETTLE TYPE REBOILER
Shell
Tubesheet
Gasket
Condensate Inlet
Condensate Oulet
Steam Outlet
FALLING FILM HEAT EXCHANGER
STEAM
Solution Inlet
HEAT EXCHANEGR SPECIFICATIONS
TEMA SPECIFICATIONS
Shell Dia.
12 450 B E M
Shell Flow Arrangement
Front Channel Head Design
Rear Channel Head Design
Tube Length
TEMA = TUBULAR EXCHANGER MANUFACTURING ASSOCIATION
FRONT HEAD ARRANGEMENT
A
B
REMOVABLE CHANNEL AND COVER
BONNET
FRONT HEAD ARRANGEMENT
C
D
SPECIAL HIGH PRESSURE CLOSURE
INTEGRAL WITH TUBESHEET
REMOVABLE COVER
SHELL SIDE FLOW ARRANGEMENT
ONE PASS SHELL
TWO PASS SHELL
WITH LONGITUDNAL BAFFLE
SHELL SIDE FLOW ARRANGEMENT
SPLIT FLOW
DOUBLE SPLIT FLOW
SHELL SIDE FLOW ARRANGEMENT
DIVIDED FLOW
KETTLE TYPE REBOILER
P Outside Packed S Floating Head with Split Ring
T Pull Through (Internal Head) W Packed with Lantern Ring
REAR HEAD DESIGN
2 - Pass Flow
Partition Plate
TUBE SIDE FLOW ARRANGEMENT
TUBE SIDE FLOW ARRANGEMENT
4 - Pass Flow
BASIC COMPONENTS - INTERNAL FEATURES
BAFFLES
TUBE-TUBESHEET JOINT
TUBES LAYOUT
BAFFLES
- Used to Support Tubes
- Creates Turbulence (Hence Enhance Heat Transfer)
- Increases Stay Time of Fluid
SALIENT FEATURES
- Increases Pressure Drop
- Creates Stagnant Point for Mud/Dirt
- Creates Operational Problem
DISADVANTAGES
BAFFLES TYPES
Horizontal Segmental Baffles
Vertical Segmental Baffles
BAFFLES TYPES
Disk & Donut Baffles
Impingement Baffles
BAFFLES TYPES
Longitudinal Baffles
BAFFLES TYPES
Rod Baffles
ROD BAFFLES
ROD BAFFLES
BAFFLES TYPES
Helical Baffles
TUBE - TUBESHEET JOINT
EXPANSION
WELDING
TUBE EXPANSION
- Shop tested up to 200 bars
- At plants, recommended pressure limit is 50 bars
- Not recommended for lethal services
- Following are two most general types;
1 Rolling Expansion
2 Hydraulic Expansion
- Rollers consist of cylindrical cage with 3 to 7 rollers
ROLLING EXPANSION
HYDRAULIC EXPANSION
- Flexible mandrel is pressurized with water which expands tube in
tubesheet hole
HEAT EXCHANGER MAINTENANCE
- Cleaning
- Testing
ROUTINE MAINTENANCE
- Repair
- General Inspection
HEAT EXCHANGER INSPECTION
- Gasket and sealing faces condition
GENERAL CHECKS
- Bolts condition
- Condition of channel head, shell etc.
- Pass partition
HEAT EXCHANGER INSPECTION
- Corrosion
TUBESHEET CONDITION
- Ligament cracking
HEAT EXCHANGER INSPECTION
TUBE CONDITION
Erosion and corrosion
HEAT EXCHANGER INSPECTION
TUBE CONDITION
Tube ends thinning and corrosion
HEAT EXCHANGER INSPECTION
TUBE CONDITION
Tube-Baffle clearance Deposits of scale and foulants
HEAT EXCHANGER INSPECTION
Bowed tubes indicating
excessive thermal expansion
TUBE CONDITION
External tube erosion
HEAT EXCHANGER CLEANING
1 Deposition of Sand, Clay, Mud
2 - Scaling
3 - Corrosion
WHY HEAT EXCHANGERS NEED CLEANING?
HEAT EXCHANGER CLEANING
1 - Chemical Cleaning
2 - Mechanical Cleaning
3 - High Pressure Jetting
ON-LINE CLEANING
OFF-LINE CLEANING
ON-LINE CLEANING
CW Inlet CW Outlet
Ball Collector
ON-LINE CLEANING
OFF-LINE CLEANING
- Usually produces better results than mechanical cleaning
- Most convenient technique (disassembly not required)
CHEMICAL CLEANING
- Can be used for soft materials
- Expensive
- Environment Hazard
- Chemicals used in FFC:
a - SalphamicAcid
b - Armohib-31
c - Soda Ash
OFF-LINE CLEANING
- Following tools are used for cleaning exchanger mechanically;
- Following exchanger cannot be cleaned;
MECHANICAL CLEANING
a Flat, flexible metallic strips
b Nylon brushes (for soft tube materials)
c - Rods
d Wire brushes
a Shell side of fixed-tubesheet units
b U-tube units with small radii
c Bundles with small tube spacing (less than 6.5 mm)
OFF-LINE CLEANING
- Usually produces better results than mechanical cleaning
- Convenient technique (bundle pulling not required)
HIGH PRESSURE JETTING CLEANING
- Can be used for soft materials
- Less material loss than chemical cleaning
- No environment Hazard
HEAT EXCHANGER TESTING
Hydraulic Test
Static Head Test
Pneumatic Test
- Pressure Test
- Leak Test
Helium Leak Test (Not Discussed)
Ammonia Test
HYDRAULIC TEST
- Suitable liquid is used as testing media e.g. water, kerosene,oil etc.
- Minimum dwell time is 30 min.
- Minimum test temperature 21
0
C.
- Maximum test temperature 49
0
C .
- For new equipment, test pressure is 1.5 x Design Pressure.
- For used equipment, test pressure may be 1.5 x MAWP or Design
Pressure or recalculated incorporating corrosion allowance.
HYDRAULIC TEST
- Test procedure for welded and expanded tube-tubesheet joints
- Testing differential pressure design exchanger
- For Stainless Steel bundles, use demineralised water
STATIC HEAD TEST
- Water level is maintained for a definite period of time
- Recommended for condensers of condensing turbines
TURBINE
PNEUMATIC TEST
- It must be avoided whenever possible
- Extremely dangerous as gases store huge energy during
compression
PRESSURE TEST
- May be used in place of Hydraulic test when:
a Foundation problem preclude the use of water
b For equipment not readily dried
c Equipment having refractory lining
d Any other reason
PNEUMATIC TEST
- Air/Gas is used to test the pressure at MAWP
- Pressure should be gradually increased to x MAWP
after that in steps of 1/10 of test pressure
PRESSURE TEST (STRENGTH TEST)
- Temperature should be maintained at least 17
0
C above
minimum design temperature
- Used to detect exact location of leakage
- Shell is pressurized with air and leakage is detect with soup solution
- Testing pressure should be lower than 2 bars.
LEAK TEST
PNEUMATIC TEST
AMMONIA TEST
- Shell is pressurized with Nitrogen (85%) and Ammonia (15%) gas
- Leakage is detected with Ammonia sensitive paper or paste
- Care should be taken while connecting gas cylinders directly
with exchanger
- Soaking time is around 10 hrs
- Leak 500 times smaller to bubble test
- Pressurization steps
1 - Pressurize with Nitrogen up to 2.0 bar
2 - Pressurize with Ammonia up to 2.3 bar
TUBE PLUGGING
Taper Plug
- Can be easily manufactured
- One sealing point (when press fitted)
- Can be press-fitted or welded
- Difficult installation when tube ends are eroded
- Included angle 5
1
/
2
0
or less (for press-fitted plugs)
- No pressure limit (for welded plugs)
TUBE PLUGGING
Two-Piece Plain Plug
- Specially designed for eroded tube ends
- Tube inside should be absolutely cleaned
- Can be press-fitted only
Ring
Plug
- Serrated ring may be used when tube cannot
be cleaned.
Serrated Plug
- Used for high pressure (than press-fitted tapered plug)
TUBE PLUGGING
Pop-a-Plug
- Can be used when tube ends are eroded
- Very quick method
- Tested up to 96 bars
- Absolute tube cleaning is required
- Remote tubes can be plugged
GOOD PLUGGING PRACTICES
- Vent tubes of process heat exchanger to prevent
pressure building
- Choose compatible material for plug
- Good cleaning before plugging
- Test exchanger after plugging
- Stabilize damaged tubes
- Welding procedure if plug is welded
PLUG MAPPING
Date
1 2 3 4
A
B
C
D
E
Tag Number e.g. C4
Location of tube failure
Cause
Any other relevant information
(axially and circumferentially
if possible)
PLATE HEAT EXCHANGER (PHE)
PLATE HEAT EXCHANGER (PHE)
Rubber Gasket Metallic Plate
Hot Stream
Cold Stream
PLATE HEAT EXCHANGER (PHE)
- Compact Design
- Used Where Hygiene is Required
- Heat Exchanging Capabilities can be Easily Enhanced
SALIENT FEATURES
PLATE HEAT EXCHANGER (PHE)
- Expensive Design
- Costly and Difficult Maintenance
- Several Joints Hence more Chances of Joint Failure
DISADVANTAGES
- Maximum pressure limits to 25 bar.
- Maximum temperature limits to 170
0
C.
PLATE HEAT EXCHANGER (PHE) PARTS
A B
A - PLATE
B - PLATE
Flow --- Top to Bottom
Flow --- Bottom to Top
PHE PLATES
PHE GASKET
MATERIAL
Rubber
01 Field Gasket
02 Ring Gasket
Links
MAINTENANCE OF PHE
- Measure width of exchanger.
Width : 10mm (02 turn per bolt)
Height : 25mm (05 turn per bolt)
OPENING
- Open bolt diagonally.
- Skewing of plate not allowed above
following limits;
MAINTENANCE OF PHE
- Cleaning of all parts especially
CLOSING
a - Sealing surfaces
- Install plates taking care of order of
b - Bolts
c - Carrying and sliding bars
a - Gasket
b - Plate
Wrong Pattern
Right Pattern
(Honeycomb Structure)
MAINTENANCE OF PHE
- Start tightening bolts alternately & diagonally
TIGHTENING
- Take care of skewing limits
- Stop tightening at required width/torque
M 24 -------- 450 Nm
M 48 -------- 3300 Nm
- Plate pack thickness must not differ more than 1%
Heat Exchangers @ TNB LPL
GT Generator Cooler
GT Lube Oil Cooler
Cooling Tower
Condenser
HRSG
CCW Heat Exchangers
THANK YOU!
FLOW ARRANGEMENT
Counter Flow
Parallel Flow
Cross Flow
TUBULAR EXCHANGER TYPES
Double Pipe
Spiral Tube
DIRECT CONTACT HEAT EXCHANGER
BACK TO BASICS
LAMINAR & TURBULENT FLOW
BAFFLES TYPES
Rod Baffles
TUBE PLUGGING
Two-Piece Plain Plug
- Specially designed for eroded tube ends
- Sealing is poorer than taper plug.
- Can be press-fitted only
Ring
Plug
HEAT EXCHANGER MAINTENANCE
TUBE FAILURE
LEAKAGE FROM SHELL / WEEPHOLE
HEAT EXCHANGER MAINTENANCE
- Impurities in fluid
TUBE FAILURE
- Absence of impingement plate (when required)
(Occurs near inlet/outlet nozzles)
- High velocities
- Excessive turbulence
- Corrosive fluid
- Due to baffle cuts