Introduction To Heat Exchangers PDF

Prepared by Faculty
Production-CG Team Y Rama Sudhakar

PNM-CG
PARADEEP REFINERY PROJECT

A Sunrise Project for a Sunshine Future
CONTENTS
 Heat exchanger
 Mechanism of heat transfer
 Heat exchangers - Different types
 Pattern of flow
 Stream allocation
 Components of Shell and tube exchangers
 Monitoring operation
 Startup & Shutdown Procedures

INTRODUCTION TO HEAT EXCHAGNERS
Heat exchanger
 Equipment used for transferring heat energy from one medium to
another
Mechanism of heat transfer

 Conduction : Without visible movement of matter
 Convection : By stream which are in motion
 Radiation: Heat transfer by electro magnetic waves in space
Heat transfer in Heat exchangers is due to Conduction and convection

3 Methods of Heat Transfer.mp4

HEAT EXCHANGER TYPES
Heat exchanger types
 Double pipe heat exchangers
 Plate heat exchangers
 Spiral tube heat exchangers
 Air coolers
 Shell and tube heat exchanger
 Fixed tube sheet
 U tube bundle
 Floating head
Shell and tube exchanger Components

 Shell, Tubes, Tie-rods, Baffles, Channel cover, Channel, Pass partition,
Tube sheet, Impingement plate, Nozzles
 Shell & Tube Type Heat Exchanger.mp4
 SHELL AND TUBE HEAT EXCHANGER NEN-TYPE (re-upload).mp4

HEAT EXCHANGER - TYPES
 Double pipe heat exchangers

 Simple design and flow distribution
 Consists two concentric pipes
 Easy maintenance
 Easy cleaning by dissembling
 Suitable for high pressure service
 Uses for small capacity application
 Uses where required heat transfer area is less
 Stacks of double pipe exchangers are in use
 Plate heat exchangers

 Exchangers are made of thin plates
 High heat transfer area
 Easy maintenance
 Fluid passes through alternative plates
 Not suitable for high pressure and temperatures
 Gasketed, Brazen and welded exchangers are in use
 Prone to leaking of gaskets

 Spiral heat exchangers

 Spirally wound coils fitted in a shell
 Heat transfer is good due to improved area
 Fouling is less
 Cleaning is not possible
 Air coolers
 Heat removal by air
 Uses when large quantity of heat removal is
required
 More cost efficient
 Air is not corrosive
 Less load in cooling towers
 Low maintenance and operating cost
 Suited for cooling high temperature fluids (>80
deg C)
 AIR COOLER HEAT EXCHANGER - ANIMATED ASSEMBLY.mp4
HEAT EXCHANGER – SHELL & TUBE
Shell and tube heat exchangers
 Used for various applications
 Uses for heat transfer with and without phase change
 Uses for variety of operating conditions
 Handles severe fouling
 Works where no other exchangers would work
 Uses for high viscous fluids
 Easy to construct and maintain
 Flexibility in MOC, Design and expertise

 Three common types of exchangers are
 U-tube exchangers
 Fixed tube sheet exchangers
 Floating head type heat exchangers
U-tube exchangers
 Removable type tube bundles
 Low cost exchangers
 Cleaning is very difficult
 Thermal expansion is possible, handles thermal stresses

HEAT EXCHANGER - TYPESNERS
U-tube exchangers

Fixed tube sheet exchangers
 Construction is simple
 Low cost exchangers
 Differential expansion not possible
 Cleaning outside of tubes is not
possible
 Can be used when inlet temperature
difference is low
 Floating head exchangers

 Removable type tube bundle
 Permits thermal expansion
 Internal and external cleaning f tubes
possible
 High cost involved

 Single pass exchanger

 One fluid passes against other
fluid only once
 Multi pass exchanger

 One fluid passes against other
fluid more than once

FLOW PATTERN
Different flow patterns in use are
 Counter current flow
 Fluids flow in opposite direction
 Co-current flow
 Fluids flow in same direction
 Cross flow
 Fluids flow in direction normal to each other
 Split flow
 Fluid enters at centre of shell splits and travels along with tubes and
takes turn and join before exiting from the centre
 Divided flow
 Fluid enters from one point and after splitting flow separately and
exits from two nozzles

FLOW PATTERN
Counter current flow
o Superior to other flow arrangement
o Most efficient flow arrangement
Co-Current flow
o High Thermal stress at one end
o Lowest wall temperature is higher
o When want to avoid condensation

Split flow exchanger
Divided flow in Exchanger

HEAT EXCHANGER - COMPONENTS
Basic components of shell and tube heat exchangers are
Baffles Tube sheet Tube bundle
Tube pass Pass partition plates Twisted tubes

Baffles
 Supports the tube and maintain tube spacing
 Increases shell side velocity and Induces turbulence
 Improves heat transfer
 Different types are baffles are in use
 Tie Rod
Supports baffles, holds the baffle assembly and maintain selected
baffle spacing
 Tubes
 Seamless and welded tubes are available
 Finned and twisted tubes uses for increasing heat transfer
 Sizing of tubes considers cleaning, pressure drop

 Channel heads
 Contains the tube side fluid and provide desired flow path
 Tube sheet
 Plate where tubes are inserted
 Tubes shall be appropriately secured to the tube sheet
 Holes in the tube sheet drilled in triangular and rectangular shapes
 Triangular pitch provided compactness and more heat transfer
 Rectangular pitch provided easiness in cleaning
 Impingement plate
 Plate provides at entry of low path to minimize impingement
 Heat exchangers principles - Complete video.mp4

 Building Heat Exchangers.mp4

SHELL & TUBE HEAT EXCHAGNER
• The more heat that can be exchanged between process streams, the smaller
lower
will be the fuel consumption and the __________ will be the cooling towers
required.
• The use of baffles will __________

increase the heat transfer rate.

FIXED TUBE SHEET EXCHAGNER
• Because there is no provision for expansion, the fixed tube sheet exchanger
would be unsuitable for uses in which the temperature difference between
large
the shell-side and the tube-side fluids was very _________.
• In this type of exchanger, it is impossible to clean the outsides of the tubes.

Thus, it would be suitable for use only with a clean, non-fouling ________shell
side fluid.

FLOATING TUBE SHEET EXCHAGNER
• The tube sheet is fixed at only one end. The other end is free to move to
allow for expansion tubes
__________ of the ___________.
• Thus, the floating tube sheet exchanger can be used when the temperature
great
difference between the two fluids is ___________.

U TUBE EXCHAGNER
• U-Tube exchanger is often used when there is a large ____________
temperature
difference between the shell-side and the tube-side fluids.
____________
• U-Tube exchangers are used in situations where the ________

tube side fluid is
clean.

• Which of the three exchangers would be best for use when the shell-side
fluid had a temperature much higher than the tube-side fluid:
 single pass, fixed tube sheet exchanger
 U-tube exchanger
 three pass, fixed tube sheet exchanger
• Which of the exchangers make allowances for the expansion of the tubes?
 U-tube exchanger
 single pass, fixed tube sheet exchanger
 floating tube sheet exchanger
 multi pass, fixed tube sheet exchanger
• In Floating tube sheet exchanger, tube bundle can be readily removed for
cleaning outside surfaces of the tubes. So this type of exchanger can be used
dirty
when both the fluids are _________ fouling
and ____________.

• By using multi-pass exchangers, the effective length of flow is increased and
higher flow velocities are possible. The greatest heat transfer rate would be
possible in the exchanger with:
 single pass on shell and tube side
 single pass on the shell side and double pass on the tube side
 double pass on the shell and tube side
• The three basic types of shell-and-tube heat exchangers are:

 the __________
fixed tube sheet type with no provision for tube expansion
 the ______________
U-tube exchanger in which the tube bends to allow for
expansion
floating
 the ___________ tube sheet type in which the tube sheet is fixed at
one end.
• If the temperature difference between the shell-side fluid and the tube-side
floating tube sheet exchanger or the
fluid is quite large, then either the ___________
U-tube
____________ tube exchanger should be used.

BAFFLES
• Baffles can be used on the shell-side of any of the basic types of exchangers.
increase
By increasing flow velocity and turbulence, baffles will ___________ heat
transfer rate.
• There are two general types of baffles used on the shell-side:

 Transverse (crosswise) baffles are used to create ____________
turbulent flow
 To make the exchanger multi-pass on the shell-side longitudinal
__________
baffles are used
• By increasing the velocity and turbulence of flow on the shell-side, baffles

heat transfer
increase the rate of _______________ between the two fluids.
• The half-moon baffle is suitable for use with fouling fluids or for large
increase the
volumes of flow. The purpose of half-moon baffles is to ___________
flow turbulence.

BAFFLES
• The three general types of baffles shown are:
 the half-moon (low pressure drop)
 the disk-and-ring (low pressure drop)
 the orifice type (high pressure drop)
Which of the three types would not be suitable for a heavy fluid with a high
orifice
flow volume? ___________

TUBE ARRANGEMENT - PITCH
• In the first configuration (A), the tubes are set in a square pattern. This is
square ___________.
called _________ pitch
• In the second configuration (B), the tubes are set in a triangular pattern.
triangular
This is called ____________ pitch
__________.
• Thus, with dirty, scale-forming fluids, ____________

square pitch must be used,
even though the best arrangements for greatest heat transfer rate would be
triangular pitch.
_____________
• A third configuration of tubes is the diagonal square (C). Diagonal square

can
pitch is similar to square pitch. The tube bundle __________ be mechanically
cleaned.

TUBE ARRANGEMENT - PITCH
• _____________
Triangular pitch configuration would result in the highest heat transfer
rate.
• For a dirty, fouling fluid in which the temperature difference was quite
large, the best heat exchanger to use would be:
 the fixed tube sheet exchanger
 floating head exchanger

HEAT EXCHANGE EQUIPMENT – GENERAL PROPERTIES
• In ordinary shell-and-tube exchangers, the more ___________
viscous fluid is
turbulent flow.
usually sent through the shell where the baffles will set up __________
rapidly and the rate of heat
In this way the viscous fluid will flow more __________
increase
transfer will ____________.
• If one of the fluids in the exchanger is a gas it will be sent through the shell-
side of the exchanger , as in a reboiler or a condenser.
shell
If the exchanger is used as a reboiler, the liquid is vaporized in the ________
side.
If vapor is cooled and liquified in the shell-side of the exchanger, the
Condenser (or reboiler)
exchanger is called a _______________________.
highest
• In general, the tube material should be the one with the __________
thermal conductivity (but limited by others factors such as cost, corrosion,
and temperature).

HEAT EXCHANGE EQUIPMENT – GENERAL PROPERTIES
• Some of the more common tube materials are carbon steel, stainless steel,
aluminium, admiralty, copper-nickel alloy, and brass. If only thermal
conductivity had to be considered in selecting a tube material, which metal
copper
would be the best? __________
• A larger area is obtained by using a greater number of the smaller diameter

tubes, but since small tubes offer more resistance to flow, the pressure drop
greater
will be ___________ in smaller tubes.
• So the ideal tube size for a give service will be the size that offers easy
maximum
cleaning and ____________ smallest pressure drop.
surface area for ___________

ALLOCATION OF STREAMS
Allocation of streams based on
 Fouling
 Fluid with high fouling factor in tubes for ease in maintenance
 Increased velocity in tubes reduces fouling
 Increases exchangers life
 Pressure
 High pressure stream in tubes
 Allocation in tube side reduces the thickness of shell
 Corrosion
 Fluid with high corrosiveness in tube side
 Less expensive, easy maintenance
 Viscosity
 Fluid with high viscosity in shell side for better heat transfer
 Phase change
 Fluid with phase change will be in shell side

MONITORING OF EXCHANGERS
Fouling
 During the operation salts, algae deposits on he surface of metal
 Deposition increases with time
 Reduces heat transfer, flow rate and increases pressure drop
 Deposited layer has maximum thermal resistance
 Higher pressure drop demands higher pumping costs
 Types of fouling are
 Precipitation fouling
 Particulate fouling
 Chemical reaction fouling
 Corrosion fouling
 Solidification fouling
 Biological fouling
 Exchanger Tube Fouling and Pitting.mp4

Precipitation fouling
 Due to crystallization of salts, oxides and hydroxides from solutions
 Particulate fouling
 Particles suspended in water deposits due to flocculation and
coagulation
 Chemical reaction fouling
 Fouling occur due to chemical reaction in fluids. Ex: Polymerization,
carbonization
 Corrosion fouling
 Fouling occur due to corrosion of material. Ex: Oxidation
 Solidification fouling
 When a component solidifies due to sub cooling. Ex: Deposition of
wax
 Biological fouling
 Undesirable accumulation of micro organisms

Fouling control
 Pre filtration of cooling water
 Water treatment (Membrane separation, Ion exchange methods)
 Controlling PH. (Ex: Alkylation)
 Removal of dissolved oxygen
 Using corrosion inhibitors
 Using chemical fouling inhibitors
 By maintaining uniform velocity
 By eliminating stagnant regions
 Back flushing
 Blow-down
 Fouling monitoring systems are in place
 Heat Exchanger Removal & Cleaning.mp4

Operation of heat exchangers
 Always operate under design conditions
 While taking in operation, first open vent and establish cold side
circulation
 Commission hot side by opening vent after commissioning cold side
 Avoid Thermal shocks while commissioning and during operation
 Take exchanger in line slowly
 Flow fluctuations shall be avoided to prevent vibrations
 Monitor P, T across exchanger with time
 Prevent hammering in exchangers by removing condensate
 Drain the hot stream completely first and cold stream next for
shutdown
 Monitor the quality of cooling water regularly to minimize fouling
 Follow Standard procedures for operation, isolation, Handing over
and taking over of exchangers

 What can go wrong
 Improper line-up of exchanger
 Un manned draining
 Lining-up hot side without lining-up cold side
 Isolation of TSV, PSV’S
 Sudden line-up of exchanger leading trip, fires and leaks
 Continuing operation of leaking exchangers
 Improper utilization of exchanger

 Opening of exchanger bypass valves
 Exchangers inline with high pressure drop
 Exchangers operation outside design conditions
 Lower tube and shell side velocities
 Improper isolation of exchangers

 isolation of exchanger without draining
 Isolation of exchanger without flushing
 Handing over of exchanger without blinding
 PARADEEP REFINERY PROJECT
HEAT EXCHANGERS - STARTUP



HEAT EXCHANGERS - SHUTDOWN

HEAT EXCHANGERS – HANDING OVER PROCEDURE

HEAT EXCHANGERS – TAKING OVER PROCEDURE

QUERIES

1. Industrial heat transfer is due to ----------------------mechanism of heat transfer
2. Most common type of heat exchangers in refinery are -------------------------------
3. Fixed tube heat exchangers are used where temperature difference is ----------------------
4. The use of baffles will __________ the heat transfer rate
5. Flow pattern in air fin coolers are --------------------------------
6. Fluid with high corrosiveness placed in -----------------------side of exchanger


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Introduction To Heat Exchangers PDF

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Prepared by Faculty

Production-CG Team Y Rama Sudhakar

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

Mechanism of heat transfer

Heat transfer in Heat exchangers is due to Conduction and convection

PARADEEP REFINERY PROJECT

Shell and tube exchanger Components

PARADEEP REFINERY PROJECT

 Double pipe heat exchangers

 Plate heat exchangers

PARADEEP REFINERY PROJECT

 Spiral heat exchangers

 Used for various applications

 Uses for heat transfer with and without phase change

 Uses for variety of operating conditions

 Handles severe fouling

 Works where no other exchangers would work

 Uses for high viscous fluids

 Easy to construct and maintain

 Flexibility in MOC, Design and expertise

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

 Floating head exchangers

PARADEEP REFINERY PROJECT

 Single pass exchanger

 Multi pass exchanger

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

Split flow exchanger

Divided flow in Exchanger

PARADEEP REFINERY PROJECT

Baffles Tube sheet Tube bundle

Tube pass Pass partition plates Twisted tubes

PARADEEP REFINERY PROJECT

 Heat exchangers principles - Complete video.mp4

PARADEEP REFINERY PROJECT

• The use of baffles will __________

PARADEEP REFINERY PROJECT

• In this type of exchanger, it is impossible to clean the outsides of the tubes.

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

• U-Tube exchangers are used in situations where the ________

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

• The three basic types of shell-and-tube heat exchangers are:

PARADEEP REFINERY PROJECT

• There are two general types of baffles used on the shell-side:

• By increasing the velocity and turbulence of flow on the shell-side, baffles

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

• Thus, with dirty, scale-forming fluids, ____________

• A third configuration of tubes is the diagonal square (C). Diagonal square

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

• A larger area is obtained by using a greater number of the smaller diameter

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT

PARADEEP REFINERY PROJECT