Heat Exchanger

SKILL IMPROVEMENT PROGRAM
HEAT
EXCHANGER
PREPARED BY:
M. ARSHAD MALIK
REORGANIZED / CONDUCTED BY:

NASEER VIRK
REVIEWED BY:
AHMAD
ZAFAR ALI KHAN
FFC TECHNICAL TRAINING CENTRE

HEAT AND HEAT TRANSFER
DEFINITION OF HEAT EXCHANGER
CONSTRUCTION
TUBES ARRANGEMENT
11
TYPES OF FLOW AND THEIR ARRANGEMENT
12
CLASSIFICATION
14
CONSTRUCTION CODE
21
START-UP AND SHUTDOWN PROCEDURES
22
MAINTENANCE
23
PRESSURE TESTING
26
PRECAUTIONS
27
LEAKAGE DETECTION AND REPAIR
28
TROUBLESHOOTING
30
HEAT EXCHANGER
HEAT
Heat is the form of energy which can be converted to other forms of energy.
It is the total kinetic energy of molecules.
Heat flows from a place of higher temperature to the lower temperature i.e. heat
flow occurs when there is a temperature difference between the bodies.
UNITS OF HEAT
Units of heat are Calorie or B.T.U
CALORIE
Amount of heat required to raise the temp. of one gram of air-free water to 1 0C.
01 Calorie = 4.2 Joules.
B.T.U.
Amount of heat required to raise the temp. of one pound of water to 1 0F.
01 Btu = 1055 joules
01 Btu = 252 Calories.
TYPES OF HEAT FLOW
CONDUCTION
Heat flow due to close physical contact of molecules e.g. in solids.
TECHNICAL TRAINING CENTER
CONVECTION
Heat flow due to the actual movement of the molecules e.g. in liquids & gases.
RADIATION
Heat flow due to the heat waves i.e. without any material medium e.g. in vacuum.
TEMPERATURE
It is the measure of hotness or coldness of a body or It is the average kinetic energy of
the molecules.
TEMPERATURE SCALES
Various scales have been developed to measure the temperature. They are:
Celsius Scale (0 0C 100 0C)
Fahrenhiet Scale (32 0F 212 0F)
Kelvin Scale (273 0K 373 0K)
Rankine Scale (4920R 6720R)
CONVERSION OF SCALES
0
5 / 9 (0F-32)
9/5 0C + 32 = 1.8 0C + 32
1.8 0K
C + 273
R 459.4
THERMAL CONDUCTIVITY
The capacity of a material to pass heat from it, is called its thermal conductivity denoted
by K. the material with high value of K is a good conductor than that of with a lower
value of K.
Its units are W/(m -0C) or Btu/(hr-ft-0F). where W=J/ Sec.
Thermal Conductivity of Various Materials
Thermal Conductivity (K)

Material
Temperature
BTU/FT-HR-0 F
Asbestos
212
0.111
Asphalt
68
0.430
Building Brick
68
0.400
Brick insulating
392
0.050
Coke
212
3.400
Cork
86
0.025
Wood Pine
59
0.087
Aluminium
212
119.000
Brass
212
60.000
Copper
212
218.000
Cast Iron
212
30.000
Steel
212
26.000
Gasoline
86
0.078
Kerosine
68
0.086
Water
86
0.356
Air
212
0.0183
Ammonia
212
0.0185
Butane
212
0.0185
Carbondioxide
212
0.0133
TEMPERATURE SCALES
HEAT TRANSFER RATE THROUGH HEAT EXCHANGER

Q
Where
U A T
Heat transfer rate.
Surface area for exchanging heat.
Co-efficient of heat transfer.
Temp. difference between the fluids.
FACTORS AFFECTING HEAT TRANSFER IN AN EXCHANGER

a. Temperature difference b/w two fluids.
b. Thermal conductivity of tube material.
c. Surface area of the tubes.
d. Flow pattern of the fluids (Laminar / turbulent).
e. Rate of flow of the fluids.
EFFECTIVE HEAT TRANSFER SURFACE
Heat transfer rate can be increased by increasing heat transfer surface. Heat transfer
surface depends on;
a. No. of tubes
b. Length of tubes
c. O.D. of tubes
Effective tube length
= Tube length length extended in tube sheet.
DEFINITION
It is equipment used to exchange heat between two fluids i.e. heat flows from the hotter
to colder fluid. The specific name is given to any heat exchanger according to its
service e.g.;
a)
Heater:
Exchanger used to hot process fluid.
b)
Cooler:
Exchanger used to cool process fluid.
c)
Condenser:
Exchanger used to liquefy vapors.
d)
Vaporizer:
Exchanger used to vaporize liquid.
e)
Pre-heater:
Exchanger used to heat process fluid to some extent,

utilizing waste heat, and prior to its actual heating process.
f)
Re-boiler:
Exchanger used tore-boil the fluid during the process

at a particular stage.
g)
Chiller:
Exchanger used to cool down a process fluid by evaporating a

refrigerant. Usually used when required cooling is unattainable by
cooling water.
CONSTRUCTION OF HEAT EXCHANGER

TUBES
O.D. Range
Commonly used
, 1
Standard tube lengths
8, 10, 12, 16 & 20 Ft.
Commonly used lengths
16 & 20 Ft.
Tube wall thickness range
18 10 BWG
Size to be taken from outside.
More flexible.
Wall thickness always measures in BWG.
Ratio, (outer diameter / thickness) is less then 20.
Tube is always seamless.
TUBE SHEETS
Single Tube Sheet (for safety factor)
Double tube sheet (for safety factor)
TUBE JOINT
Welded
Rolled
SHELL
Outer hollow piece.
BAFFLES
Baffles are used to:
Support the weight of tubes.
Increase the turbulence of fluid.
Two Basic Types of Baffles:

1. LONGITUDINAL BAFFLES
There are long rectangular plates used to split the

flow on the shell side.
2. TRANSVERSE BAFFLES
These are cross-sectional baffles like round plated

used to create turbulence in flow.
The names of different types of transverse
baffles are segmental baffles (half moon baffle) Disc and Doughnut type, impingement
type baffles.
TIE- RODS
They support baffles.
BONNET / CHANNEL / HEAD
Used to feed or collect the tube side fluid.
GASKETS
Three types of gaskets are commonly used;

a. Asbestos Gaskets.
b. Soft Iron / Aluminum Gaskets.
c. Metal covered asbestos Gasket (Jacketed Gasket).
10
TUBE SHEET LAY-OUT

PITCH
Pitch can be defined as the shortest distance between centers of two consecutive
tubes.
LIGAMENT
Ligament or Clearance can be defined as the shortest distance between two adjacent
tube holes.
Triangular Pitch
In-line triangular pitch or Rotated
Square Pitch
Diamond Square or Rotated Square
TYPE OF PITCH
Triangular Pitch
ADVANTAGES
DISADVANTAGES
Faster heat transfer.
- Higher Pressure drop.

- Difficult to clean.
Square Pitch
- Low Pressure drop.
Less heat transfer.
- Easy Cleaning
11
Shell
I. D
(Inches)
SQUARE PITCH
Number of
Passes
2
4
TRIANGULAR
PITCH
Number of
Passes
1
2
4
20
241
236
224
269
260
250
22
300
280
280
337
330
314
24
360
350
336
421
404
380
26
424
412
402
499
476
460
28
402
488
480
579
562
542
30
580
566
566
668
648
636
32
665
648
644
766
744
732
34
756
758
730
870
850
834
36
853
848
832
986
978
942
38
973
950
938
1108
1100
1060
40
1085
1064
1052
1236
1228
1200
42
1201
1176
1162
1367
1350
1322
No. of tubes in different pitch arrangements
TYPES OF FLOW
LAMINAR FLOW
If the fluid flows in smooth stream lines, it
is called laminar flow.
TURBULENT FLOW
If the fluid flows in such a way that there is
a great deal of mixing in it, is the turbulent
flow.
12
SHELL SIDE FLOW ARRANGEMENT
Single-pass flow:
Fluid enters at one side & leaves at

the opposite.
Double pass flow:
Fluid enters & leaves at the same

end.
Split flow:
Fluid is divided into two separate

streams.
Double split flow:
Fluid is divided into four separate

streams.
Divide flow:
Fluid enters at the centre of

exchanger and leaves at the ends.
TUBE SIDE FLOW ARRANGEMENT

SINGLE PASS FLOW
When fluid enters at one end of tubes & leaves at
the other end.
DOUBLE PASS FLOW
When fluid enters at one end, re-directed at the
other end & leaves the exchanger at the entering
end.
MULTIPLE PASS FLOW
When the No. of passes are more than two, it is
called multiple pass flow.
13
CLASSIFICATION OF HEAT EXCHANGER
By Construction.
By Flow arrangement.
BY CONSTRUCTION:
Shell and tube Heat Exchanger (Tubular Type).
Plate Heat Exchanger.
Plate Fin Heat Exchanger.
Tube Fin Heat Exchanger.
a) The three basic types of shell and tube exchanger

i)
The fixed tube sheet exchanger
ii)
The floating head or floating tube sheet exchanger.
iii)
The U Tube exchanger or Hair Pin exchanger.
THE FIXED TUBE SHEET EXCHANGER
The tube sheet in this exchanger are fixed or immovable Thus, this type of shell and
tube exchanger is called Fixed tube sheet exchanger.
14
ADVANTAGES
The fixed tube sheet exchanger has the advantage of being less costly than more
complicated exchangers.
The fixed tube sheet exchanger would be
useful only if the temperature difference between the two process fluids is small.
It can be used where shell side fluid is clean.
DISADVANTAGES
First major disadvantage of this type of exchanger is that there is no provision made for
expansion of the tubes, as the tube sheet in this exchanger are fixed or immovable.
Thus the exchanger would be unsuitable for uses in which the temperature difference
between the shell side and tube side fluid is very large.
In this type of exchanger it is impossible to
clean the outside of the tubes because of inaccessibility of the outside surface of the
tube. Thus it would be useful for use only with a clean, non-fouling shell side fluid.
THE FLOATING TUBE SHEET EXCHANGER
The tube sheet in this type of exchanger is fixed at only one end the other end is free to
move and to allow for expansion of tubes. This exchanger is some time called the
PULL THROUGH TYPE because the entire tube bundle can be pulled out.
The floating head tube sheet exchanger can
be used when the temperature deference between the two fluid is quite large. Like fixed
tube sheet exchanger, this exchangers tube and shell side can also make 2 or 4 pass,
thus the length of path for the fluid flow on shell and tube side can be increased without
increasing the length of the exchanger, higher flow velocities could be achieved.
15
The tube bundle of the pull through type

exchanger can be readily removed for the cleaning of the out side of the tube. The
tubes are easily cleaned inside also, so this exchanger can be used when both the shell
side and tube side fluid are dirty and fouling.
THE U - TUBE EXCHANGER OR HAIRPIN EXCHANGER
In this type of heat exchanger shown in figure below, the bends in the tubes acts like
expansion bends in piping, thus the hairpin or U tube exchanger can be used where the
temperature difference between the shell side and tube side fluid is quite large.
The tubes in U tube exchanger have sharp
bends in them, the inside surface are very difficult to remove. That is why these
exchangers are used in situation where the tube side fluid is clean. Out side of the tube
(tube surface) can be cleaned by pulling the tube bundle from shell.
b) PLATE HEAT EXCHANGER
Modern heat exchangers of this kind are constructed from a number of plates that are
assembled in pairs to form large flat boxes. One substance flows between two plates,
16
mainly via ridges fitted to the plates. The other substance then flows at the other side of
these plates. The plates are separated from each other by packing. The pairs of plates
pressed against each other are so designed and perforated that e.g. one substance
flows in then arrow spaces between plates 1 and 2, 3 and 4, 5 and 6, etc. and the other
between plates 2 and 3, 4 and 5, 6 and 7 etc.
A packing flange (gasket) is fitted between each two successive plates.
Although
plate
heat
exchangers
are
sometimes used when one of the substances is a gas or if one of them condenses,
heat exchangers of this kind are used chiefly for passing heat from one liquid to
another.
Because of the narrow gap between the plates
the risk of pollution is high (partly through the deposit of solid particles). Fortunately,
plate heat exchanger is easy to dismantle and clean. A further advantage is that the
overall coefficient in this kind of apparatus is generally higher than in tube heat
exchangers. Furthermore, minor changes in the heat exchanging surfaces can be
easily make, e.g. by adding or removing plates.
FLOW ARRANGEMENT
Parallel Flow Heat Exchanger (co-current flow).
Counter Flow Heat Exchanger.
Cross Flow Heat Exchanger.
17
TWO TYPES OF FLOATING HEAD EXCHANGERS

OUTSIDE PACKED STUFFING BOX
a. Shell side fluid is sealed by a packing follower ring.

b. Packing allows tube sheet to float.
c. Leakage through packing do not mix the fluids; rather shell side fluid flows to
environment.
OUT SIDE PACKED LANTERN RING
a. Both shell side & tube fluids are sealed by separate packing.
b. Both packing are separated by a lantern ring having weep holes.
c. Both leakages occur to flow to environment.
18
SHELL & TUBE HEAT EXCHANGERS

S/N
1.
NAME
Fixed tube
exchanger.
ADVANTAGE
DISADVANTAGE
sheet Less costly
Unsuitable when T of
fluids is higher.
Simple
Minimum chance of shell Tube bundle cannot be
side leakage.
cleaned externally
Minimum shell diameter Cannot handle dirty fluid
required for a given heat on shell side.
transfer.
2.
Floating Head or Useful even for quite high Greater

required.
Pull through type.
T of fluids.
maintenance
Can be cleaned on the

outside of tubes.
Can handle dirty fluid.
3.
U-tube or Hair-pin Can be used

Exchanger.
T of fluids.
for
high Difficult to clean on

inside of the tubes
(useful for only clean
fluids)
Most economical & simplest Difficult

to
replace
construction
amongst individual tubes.
removal bundle exchangers.
Least expensive.
19
FLUID ALLOCATION
S/N
TYPE OF FLUID
1.
Viscous Fluid
2.
Toxic &
Fluids.
Lethal
TUBE SIDE
SHELL SIDE
REASON
(Double
As
leakage
into
environment can be
prevented.
tube sheet is
also used).
3.
Slow
fluids.
moving
4.
Corrosive fluid.
5.
Fouling Fluid
6.
Hotter fluid
High temp. requires

expensive
material
which are required
lesser on tube side.
7.
High
fluid.
Pressure
Generally tube side is

used because of the
reason as above in
No. 6.
8.
For Fluid with

lower
allowable
pressure drop.
For same pressure

drop, higher heat
transfer is obtained
on the tube side.
Better
turbulence
exist on the shell
side.
Less cost on the
required material /
cladding.
Better fluid velocity
reduces fouling in
tubes.Also, chemical
cleaning is effective
on the tube side.
20
CONSTRUCTION CODE
Rules for construction of pressure vessels, Div I Section VIII of A.S.M.E. Boiler &
Pressure vessel Code.
TEMA (Tubular Exchanger Manufacturer Association.)
API (American Petroleum Institute).
CLASSES OF HEAT EXCHANGER (TEMA STANDARD)

CLASS R
For Petroleum Processing application.
CLASS C
Moderate requirements of commercial & general process application.
CLASS B
For chemical process services.
MATERIAL
Shell
:
Carbon Steel
Tube
Alloy Steel
Tube Sheet :
Carbon Steel (and/or cladded with alloy steel).
EXCHANGERS SPECIFICATION
Exchanger is specified by
Size
Type
a.
Exchangers size is specified by the following (as per T.E.M.A; Turbular

exchanger manufacturers association).
Diameter of the shell
Length of the tubes
b.
Types are specified by letters of alphabet, e.g.
A, B, C, D
Four designations of stationary head types.
E, F, G, H, J, K
Shell types.
Kettle type re-boiler.
L, M, N, P, S, T, U
Rear head types.
EXAMPLE:
Suppose there is a fixed tube sheet exchanger having stationary head and rear head
integral with the tube sheets, single pass shell, 17 inch inside diameter and tubes are
16 feet long. Its designation would be:
17-192 type CEN
21
BRIEF STARTUP PROCEDURE

VENTING & FILLING
All valves and drains should be closed before starting up. Only vent valve should
be open.
First introduce the cooler fluid by crack opening tube-side inlet valve. (let us
suppose cooler fluid is in the tube side).
Crack open the tube-side inlet vent valve. After venting is completed, close it.
Repeat procedure at tube side outlet vent.
After filling & venting of tubes, open inlet tube side valve fully.
Repeat venting procedure on the shell side.
STARTING
Crack opens the cold side outlet valve & waits for flow to start.
Fully open the valve.
Repeat step (1) & (2) for hot side fluid.
BRIEF SHUTDOWN PROCEDURE

Shutdown procedure is, in general, reverse of the start-up procedure.
Fully close the hot side outlet valve.
Fully close the hot side inlet valve.
Vent the hot side of exchanger.
Repeat above three steps for cold side fluid.
NOTE
Heat exchanger may be left full & pressurized so that it can be started again more
quickly.
Improper venting during start up can produce air-pockets in exchanger resulting in

lower efficiency.
22
MAINTENANCE
Inspection
Fouling Preventing
Cleaning
Tube bundle Removal and Handling
Gasket replacement
Pre- arrangements
INSPECTION OF UNIT
At regular intervals, the examination of inside and outside of the tubes & other parts be
made to check any sedimentation, corrosion, leakages & overall condition of parts.
FOULING PREVENTION
FOULING OF HEAT EXCHANGERS
Fouling is deposition of undesirable materials on

the Heat Exchangers surface which increases
resistance to heat transmission. Fouling is a
complex phenomenon and may be due to
sedimentation, crystallization, chemical reaction,
polymerization, coking, growth of organic
materials such as algae and corrosion. These
fouling mechanisms may operate independently
of each other or in parallel. The rate of fouling is
controlled by physical and chemical relationship
that in turn, are affected by the operating conditions. The important variables that have
important affect on fouling pressure;
FLOW VELOCITY
Very strong to moderate affect on a majority of fouling
processes.
SURFACE TEMPERATURE
BULK FLUID TEMPERATURE
MATERIAL OF CONSTRUCTION
SURFACE RUGHNESS
Affects most fouling processes and in particular

crystallization and chemical reactions.
affects rate of reaction and crystallization.
possible Catalytic action and corrosion.
Size and density of cavities will affect crystallization

nucleation, sedimentation and adherence tendency of deposits.
As fouling decreases the heat transfer rate or

flow rate, it is prevented in the following ways;
23
Use of Antifoulants prevents the formation of deposits.
Use of Inhibitors prevent chemical reactions which might cause deposits to build
up.
Smoothness of surfaces prevents the deposits which are formed in cavaties.
Flow velocity also tends to inhibit fouling.
The major fouling mechanism are;
Precipitation Fouling.
Particulate Fouling.
Chemical Reaction Fouling.
Corrosion Fouling.
Biological Fouling.
CLEANING OF HEAT EXCHANGER
Chemical Cleaning.
Mechanical Cleaning.
Hydroblasting or H.P. jetting.
a) CHEMICAL CLEANING
Most of the chemical cleaning techniques are employed while the exchanger is in
operation. This is called on-line maintenance.
Some Techniques are:
Circulation of hot wash oil or light distillate or hot fresh water through tubes or shell
at high velocity.
Chemicals can be added to the fluids in tube or shell side to remove deposits.
Commercial cleaning components are available for removing sludge, scale etc.
which can be used after the exchanger is dismantled. e.g. OAKITE & DOWELL.
b) MECHANICAL CLEANING
The exchanger must be dismantled fully or partially for mechanical cleaning techniques.
Some procedures are:
Turbine type tube cleaner are used for inside the tube cleaning.
Rotating wire brushing or roding is done to remove hard scales, coke or other
deposits.
Scrapers, drills and other devices can be used to cut and remove the hard
deposits.
24
c) H.P. JETTING / HYDROBLASTING
In this method, a high-pressure jet of water is sprayed outside or inside (usually inside
only) of the tubes. The force of water loosens the deposits and ultimately wash it away.
TUBE BUNDLE REMOVAL AND HANDLING

To avoid possible damage during removal of a tube from a shell, a pulling device should
attached to eyebolts screwed into the tubesheet. If the tubesheet does not have tapped
holes to 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 the tubes.
Gasket and packing contact surfaces should be protected.
GASKET REPLACEMENT
Gaskets and gasket 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 so doing they are work hardened and, if reused, may provide an
impact seal or result in deformation an damage to the gasket contact surfaces of the
exchanger.
Bolt 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 gasketed joint should be rectified and not permitted to persist
as it may result in damage to the gasket surfaces.
Metal jacketed type gaskets are widely used. When these are used with a
tongue and groove joint without a nubbin, the gasket should be installed so that the
tongue bears on the seamless side of the gasket jacket. When a nubbin is used, the
nubbin should bear on the seamless side.
PRE-ARRANGEMENTS
Scaffolding Requirement.
25
Requirement to Support lines.
Accessibility for crane/chain blocks.
Availability of test rings.
Pressure test assembly (with calibrated PI).
Testing procedure (Isolation blinds, pressure test blind).
Pressure value if hydraulic tensioning equipment is used.
Necessary spares (gaskets, nut/bolts ferrules, plugs, electrodes etc.).
Necessary tools.
Weights of different components.
Welding procedures for seal weld repair and tube plugging.
PRESSURE TESTING
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 the tube side are to be tested separately
in such a manner that leaks at the tube joints can be detected from at least one side.
When the tube side design pressure is the higher pressure, the tube bundle shall be
tested outside of the shell only if specified by the purchaser and the construction
permits. Welded joints are to be sufficiently cleaned prior to testing the exchanger to
permit proper inspection during the test. The minimum hydrostatic test pressures at
room temperature shall be 1.5 times the design pressure, corrected for temperature,
except where other Code requirements govern.
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 pa pressure testing medium. The pneumatic test pressure at
room temperature shall be 1.25 times the design pressure, corrected for temperature,
except where other Code requirements govern.
26
PRECAUTIONS
Never clean the tubes one by one by introducing steam through them. It cause
thermal shock to the tubes.
In packed floating head exchangers, a leakage 5-10 drops per minute is normal.
Dont try to eliminate it. Over tightening can restrict the floating action.
During pulling the bundle or mechanical cleaning, care should be taken to avoid
tube damages.
Never support the bundles on tubes during maintenance. Support on baffles &
tube sheets.
Special care should be taken on gasket surface for any scratch or damage.
Use criss-cross method of bolting / unbolting. Over tightening / wrong tightening

causes leakage.
Direct hit of high pressure jet (H.P. Jetting) can cause serious injury or death.
Always corden off the area & install Tarpaulin at both ends.
Do not remove any part of exchanger e.g. channel cover etc. until both sides are
completely depressurized & drained.
27
LEAKAGE DETECTION & REPAIR

Leakage can be detected in the exchanger by various means. Some methods are:
SAMPLE ANALYSIS
By analysing the sample of the fluid which is on lower pressure side, leakage can be
detected.
BY PRESSURE TESTING
By pressurising the shell side with water and observing any leakage from any of the
tube at the tube ends at tube-sheet. Water will come out of the damaged tube.
LOCATING TUBE LEAKS
The following procedures may be used to locate
perforated or split tubes and leaking joint between tubes
and tube sheets. In most cases, the entire front face of
each tube sheet will be accessible for inspection. The
point where water escapes indicates a defective tube or
tube-to-tube sheet joint.
Units with removable channel cover; Remove channel
cover and apply hydraulic pressure in the shell.
Units with bonnet type head: for fixed tube sheet units
where are an integral part of the shell, remove bonnet
and apply hydraulic pressure in the shell. For fixed tube
sheet units where tube sheets are not an integral part of the shell and for units with
removable bundles, remove bonnet, re-bolt tube sheet to shell or install test flange or
gland, whichever is applicable, and apply hydraulic pressure in the shell. See figure
E-4.13-1 for typical test flange and test gland.
28
Units with Type S or T floating head: Remove channel cover or bonnet, shell cover and
floating head cover. Install test ring and bolt in place with gasket and packing. Apply
hydraulic pressure in the shell. A typical test ring is shown in Figure E-4.13-2. When a
test shell cover and applying hydraulic pressure in the tubes. Leaking tube joints may
then be located by sighting through the tube lanes. Care must be exercised when
testing partially assembled exchangers to prevent over extension of expansion joints or
overloading of tubes and / or tube-to-tube sheet joints.
Hydrostatic test should be performed so that
the temperature of the metal is over 60 F unless the materials of construction have a
lower nil-ductility transition temperature.
0
LEAKAGE REPAIR
The leaking tube can be repaired by;
Plugging at both ends with a tapered plug.
Replacing the damaged tube, when a large no. of tubes are leaking or plugged.
Some times tube-ends are loosened in the tube-sheet. It is repaired by re-rolled

pressing or welding in the tube-sheet.
During each repair, normally gaskets are also replaced.
29
TROUBLE SHOOTING
BASIC TROUBLES
Leakage
S/N
Unsatisfactory Performance.
PROBLEM
POSSIBLE CAUSES
REMEDY
1.
Low heat transfer.
Fouling
Internal leakages or by passing.
2.
Mixing of fluids
By passing through tube sheet.

Damaged tubes.
-
3.
Under
performance, Repeated damage to
same tubes.
Maldistribution
of liquid into the tubes.
-
4.
De-shaping
of exchanger. (Fixed tube
sheet).
5.
Leakage through lantern ring in floating head exchangers.

-
6.
Damage to discharge lines and knocking of

tubes in condensors.
Tube leaks at baffle penetration,
U-bends
and near tube sheets.
Maldistribution
of liquid in shell side
(some tubes are
hotter
&
more
expand relatively)
Losseness of bolts.
Damaged packing
Thermal shock due
to malfunction.
Hydraulic
hammering.
7.
Vibration damage.
8.
Leaking gasketed joints.
Improper unbolting or tightening.

Scratches on mating
surfaces or dirt.
Mechanical/Chemical
Check for erosion /
corrosion at gasket
bearing surfaces or
channel baffles.
Welding/re-rolling of
tube ends in tube
sheet.
Replace/Plug
the
tube.
Use of distributor.
Use
of
eccentric
reducers instead of
concentric reducers
at the inlet / outlet of
heat exchanger.
Proper
distribution
arrangement.
Tightening of bolt.
Replace over sized

steam
trap
with
correctly sized one.
Wire lacing of tubes.
Sliding
flat
bars
between the tubes.
Changing the flow
pattern to divided /
split flow.
Use
criss-cross
method for bolting /
unbolting in several
passes.
30

Heat Exchanger

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Heat Exchanger

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SKILL IMPROVEMENT PROGRAM

REORGANIZED / CONDUCTED BY:

ZAFAR ALI KHAN

FFC TECHNICAL TRAINING CENTRE

DEFINITION OF HEAT EXCHANGER

TYPES OF FLOW AND THEIR ARRANGEMENT

START-UP AND SHUTDOWN PROCEDURES

LEAKAGE DETECTION AND REPAIR

It is the total kinetic energy of molecules.

Heat flow due to close physical contact of molecules e.g. in solids.

TECHNICAL TRAINING CENTER

TECHNICAL TRAINING CENTER

Celsius Scale (0 0C 100 0C)

Fahrenhiet Scale (32 0F 212 0F)

Kelvin Scale (273 0K 373 0K)

Rankine Scale (4920R 6720R)

TECHNICAL TRAINING CENTER

Thermal Conductivity (K)

TECHNICAL TRAINING CENTER

TECHNICAL TRAINING CENTER

HEAT TRANSFER RATE THROUGH HEAT EXCHANGER

Heat transfer rate.

Surface area for exchanging heat.

Co-efficient of heat transfer.

Temp. difference between the fluids.

FACTORS AFFECTING HEAT TRANSFER IN AN EXCHANGER

Effective tube length

TECHNICAL TRAINING CENTER

= Tube length length extended in tube sheet.

Exchanger used to hot process fluid.

Exchanger used to cool process fluid.

Exchanger used to liquefy vapors.

Exchanger used to vaporize liquid.

Exchanger used to heat process fluid to some extent,

Exchanger used tore-boil the fluid during the process

Exchanger used to cool down a process fluid by evaporating a

TECHNICAL TRAINING CENTER

CONSTRUCTION OF HEAT EXCHANGER

Standard tube lengths

8, 10, 12, 16 & 20 Ft.

Commonly used lengths

Tube wall thickness range

Size to be taken from outside.

Wall thickness always measures in BWG.

Ratio, (outer diameter / thickness) is less then 20.

Tube is always seamless.

TECHNICAL TRAINING CENTER

Single Tube Sheet (for safety factor)

Double tube sheet (for safety factor)

Outer hollow piece.

Baffles are used to:

Support the weight of tubes.

Increase the turbulence of fluid.

Two Basic Types of Baffles:

There are long rectangular plates used to split the

These are cross-sectional baffles like round plated

TECHNICAL TRAINING CENTER

They support baffles.

BONNET / CHANNEL / HEAD

Used to feed or collect the tube side fluid.

Three types of gaskets are commonly used;

TECHNICAL TRAINING CENTER

TUBE SHEET LAY-OUT

In-line triangular pitch or Rotated