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ABSTRACT
a piece of equipment built for efficient heat transfer from one medium to another.
The media may be separated by a solid wall, so that they never mix, or they may
be in direct contact. They are widely used in space heating, refrigeration, air
refineries, natural gas processing, and sewage treatment. One common example
of a condenser is the radiator in a car, in which the heat source, being a hot
engine-cooling fluid, water, transfers heat to air flowing through the radiator (i.e.
INTRODUCTION
from the hot fluid to a cold fluid or vice versa, with maximum rate and
the point where it will become a liquid by the transfer of heat to another
fluid without intermixing the fluids. Water or air is used to condense the
vapour.
COMPONENTS OF CONDENSERS
The figure given below shows a typical condenser and its components
sheet
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3. Stationary Head Flange 18.Floating Head Baring
8. Shell External
Plates
17.Floating Head Flange
2.1 TYPES OF CONDENSER
classifieds
as.
a. Regenerators.
b. Recuperator
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I. Direct Contact Condensers.
HOT WATER
Figure 2
mixing of hot and cold fluids and transfer of heat and mass takes place
fluids.
a. Regenerator
parameters
b. Recuperators
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These condensers are used when two fluids cannot be allowed to mix i.e.,
1. Easy construction
2. More economical
' In parallel flow condenser as the name suggest the two fluid streams
(hot
and cold) travel in the same direction. The two streams enter at one end
and leave at the other end. The flow arrangements and variations of
difference between the hot and the cold fluid goes on decreasing from
inlet to outlet. Since this type of condensers needs a large areas of heat
axis. FIGURE 3
The hot and cold fluid enters the opposite ends. The flow arrangements
maximum rate of heat transfer for a given surface area. Hence such
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ii. Cross Flow Condenser
In cross flow condensers the two fluids (hot and cold) cross one
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COLD FLUID
(!N)
COLD FLUID
(UOT)
13
COLD FLUID (UOT)
Figure 5
Refer Figure : Hot fluid flow in the separate column and there is
mixing in the fluid streams. The cold fluid is perfectly mixed as its flow
uniform across any section, and will vary only in the directions of the
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Refer figure: In this case each of the fluid follows a prescribed path and is
classified as under
i. Concentric Tubes
In this type, two concentric tubes are used each carrying one of the fluids.
The
In this type of condenser one of the fluid flows through a bundle of tube '
enclosed by a shell. The other fluid is forced through the shell and it flows
where reliability and heat transfer effectiveness are important. With the
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Multiple parallel and counter flow passes are used for enhancing the
overall heat transfer. Multiple shell passes is possible where the fluid
flowing through the shell is re-routed. The shell side fluid is forced to
flow back and forth across the tubes in the by baffles. Multiple tube pass
exchangers are those which re-route the fluid through tubes opposite
direction
Figure 7
These are special purpose condensers and have a very large transfer
surface area per unit volume of the exchanger. They are generally
the fluids is much smaller than that associated with the other fluid.
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4. PHYSICAL STATE OF FLUIDS.
Depending upon the physical state of the fluids the condensers are
classified as follows :
i. Condenser
ii. Evaporators
i. Condenser
gradually increases from inlet to outlet. The hot fluid losses latent part of
ii. Evaporators
the temperature of the hot fluid gradually decreases from inlet to outlet.
curtailed
improper start up and shut down practices. Some common problems are :
shell
ii. Bending of the pass partition plate in the partition channel due to
slung
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flow from the tube inlet nozzle. Caused by rapid opening of the
channel
inlet valve.
iii. Introduction of tube side fluid in a fixed tube sheet condenser with
the shell side empty (since the resulting change in the tube metal
temperature may over stress the tube to tube sheet joint resulting in
the failure).
integral
avoid
pressure is the shell and the tube side pressure are always presents
simultaneously. The
is never violated. Including the period of start up and shut down, or the
rapid tube failure, corrosion and erosion of the tube wall, tube joint
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Operating problems in condensers may be broadly classified into
three groups.
i. Structural Problems
i. Structural Problems
Structural problems are the most serious; failure is often swift and
tubes over shadow all other structural failures. Tube to tube sheet joints
in the tube sheet or cover in multiple pass design induces joint leakage.
structural problems.
Deposition of foul ants on the inside of the tube surface reduces the
available flow area and increase the skin friction, causing an increase in
tubes usually occur in units with low flow velocity design. Uneven
fouling may occur on the shell side of the tubes due to a poor baffling
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scheme. Which leads to a flow misdistribution. Highly non-uniform
Stress corrosion, galvanic corrosion, and erosion are the most requently
Advantages
1. Energy Savings.
operations.
Disadvantages
1. Friction losses
3. Failure of condenser.
2.4 FOULING
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In a condenser during normal operations the tube surface gets
covered by deposits of ash, soot, and dirt and scale etc. This phenomenon
fouling Processes
4. Corrosion fouling
5. Biological fouling
6. Freeze fouling
1. Velocity
2. Temperature
3. Water chemist
4. Tube materia]
Prevention of fouling
1. Design of condenser
exchang*
1 Physical properties
.
2 Mechanical Properties
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3 Climatic Properties
.
4 Chemical Environment
.
5 Quality of Surface
. finish
6 Service File
.
7 Freedom from Noise
.
8 Reliability
.
Common failure to condensers
tubes.
Inner surface,
Ui
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1/hi + ri/k In (ro /ri) + ri/ro x 1/ho
Outer surface
Uo
Where
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Ui Overall heat transfer coefficient inside the
tube
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Uo = Overall heat transfer coefficient outside the
tube
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Hi = Local convective heat transfer coefficient inside the
tube
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ho = Local convective heat transfer coefficient inside the
tube
ri = Inside radius of the
tube
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ro Outside radius of the
tube
k = Conductive heat transfer coefficient of tube material.
U.A. = UoAo
Where
0 o '
1 i n o Vn ) 1
hi Ai 2TTKL
h0A Figure 8
thickness and thermal conductivity of the scale deposits, the effect of sale
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coefficient hs. If hsj and hsQ be the heat transfer coefficient for the scale
on the inside surface (RSj) and outside surface (RS0) are given
thus
defined as :
R f = ( l / h r ) = l / U H . t - 1/U .
There are various types of services in which tubular exchangers are used
in
which
the
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point where it will become a liquid by the transfer of heat to
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material, and there must be tensile stresses above some minimum
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Aluminum and stainless steel are well known for stress corrosion
components.
Failures of Condensers
• Welding
• Fabrication
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• Improper design
• Improper materials
• Pitting
• Corrosion fatigue
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General corrosion
Crevice corrosion
Design errors
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Selective leaching, or
oying
dealt
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Erosion corrosion
Wear Failures
commonly used.
Adhesive wear
Erosive wear
surface due to relative motion in contact with a fluid that contains solid
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particles. More than one mechanism can be responsible for the wear
Pitting Corrosion
typified by the formation of holes or pits on the metal surface. Pitting can
Pits may be rather small and difficult to detect. In some cases pits may be
masked due to general corrosion. Pitting may take some time to initiate
methods for reducing the effects of pitting corrosion are listed below:
listed below:
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• Coatings
• Inhibitors
• Cathodic protection
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Figure.11 Uniform Corrosion
Corrosion Failures
deterioration of the material and its properties. This may result in failure
• Type of corrosion
• Corrosion rate
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necessitates a tensile stress, which may be caused by residual stresses, and
Aluminum and stainless steel are well known for stress corrosion
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Corrosion Failures Analysis.
to, foreign matter and/or surface layer of the metal is beneficial in failure
below:
• Uniform corrosion
• Pitting corrosion
• Intergranular
corrosion
» Crevice corrosion
• Galvanic corrosion
Fatigue Failures
the material. Metal fatigue cracks initiate and propagate in regions where
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Initial crack initiation
across
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Final sudden fracture of the remaining cross section
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Cycles to
Failure N
Stress
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Graph-1 S-N curve
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Schematic of S-N Curve, showing incr.ease in fatigue life with decreasing
stresses
Stress Ratio
The most commonly used stress ratio is R, the ratio of the minimum
•If the stresses are partially reversed, R = a negative number less than
1.
zero.
Variations in the stress ratios can significantly affect fatigue life. The
component will fail at lower alternating stress than it does under a fully
reversed stress.
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Preventing Fatigue Failure
improvements in design:
manufacturing.
loads below the static yield strength. This can result in an unexpected and
Creep occurs under load at high temperature. Boilers, gas turbine engines,
and ovens are some of the systems that have components that experience
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Failures involving creep are usually easy to identify due to the
Creep of Metals
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Fract
ure
1.
Strai
Initial
Load Time
----------
Graph-2 strain-time curve
period of time. The slope of the curve, identified in the above figure, is the
strain rate of the test during stage II or the creep rate of the material.
deformation takes place and the resistance to creep increases until stage II.
Stress Rupture
stresses used are higher than in a creep test. Stress rupture testing is
always done until failure of the material. In creep testing the main goal is
to determine the minimum creep rate in stage II. Once a designer knows
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the materials will creep and has accounted for this deformation a primary
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Stress
Typical
Stress M
W2 ir5 105 101 W Stress Rupture DataO
■ P i ' I I Tw,
rupture time, hr ters
Stress rupture tests are used to determine the time to cause failure.
extrapolate time to failure for longer times. Changes in slope of the stress
Channel covers are usually circulars in design and fabricated out of the
same
plate material as the channel. The thickness of the flat channel covers in
against the channel cover. Only the code formula needs be considered.
measured at the bottom of the pass partition grove minus the tube side
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required to be provided with approximately 3/16 " (408m) deep groves
CHAPTERS CAUSES
OF FAILIURE
5.1 Vibration
phenomenon as
condenser sizes and quantities of flow have increased .The shell side flow
consideration
Vortex shelling
tubes may coincide with a natural frequency of tube and excite large
velocity exceed and the vibration then become self exited and grows in
Pressure fluctuation
5.2 Corrosion
causes corrosion.
is 229°c.
The heating fluid hot oil called Therminol passess through the
tubes. The inlet of hot oil is at top of the bundle and outlet is at the bottom
The inlet temperature of the hot oil is 320 °c. and the outlet temperature is
During when the hot oil will be pass through the tubes this converts the
heat transfer (h) is less. This causes the top 120 ube become overheat.
CHAPTER-6
TYPE OF FAILURE
6.1Tube bracking
brakeage
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6.2Fracture in the weld portion
The clearance between the parallel and counter flow bundle can
6.3Tube bending
The clearance between the parallel and counter flow and over
'R'
two fluids)
P = (TCo-Tci)/ (Tho-
T c i ) = (230-217)/
(320-217) -0.126
R - (Tho-Thj)/ (Tco-
Tci) = (320-270)/
(230-217) = 3.8
=1 LMTD =1*68.87
=69.87°c
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A .consider flow inside the tube
viscosity) = (4*0.153)/
(3.14*0.01483*20* 10 ~4) =
6578.28
= 0.0238*Re08 Pr04
of hot oil)
(20*10"483.318*103)/0.H
08 = 59.89
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Nu = 0.023*6571.28 08*59.89 0 4
=138.9
(138.69*0.1108)/0.01
483 = 1036.2w/m2k
= (3*
10"4*2.356*103)/0.116
7 = 188.13
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3
Gr = (6.089 *0.00176*9.81 *71.5)/
( 11.34*10'3)2 =2.878*106
Where
'L'=6.689m (3 =
volumetric expansion=l/T
= 1/(295+273) = 1.760*
10"3k"'
(320+270)/2=295°c
temp =295-
((230+217)/2) =71.5°c
0.539*109
1/4
Nu = 0.53(Gr*Pr) for (104<
Gr*Pr>109) =0.53(0.539*109
*188.18)025 =87.42
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Nu=h0d0/k
h0 =(87.42*0.116)/ (19.05*10~3)
=494.74w/m2k
(0.01905/0.01483)) +
(1/494.724))
=290.0599w/m2oc
=2.356kj/kgoc Tco
Q =17.98*2.356*10 3*(230-217) =
550521.28w
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Heat transfer rate hot fluid
Q = mh cph (Th0-Thi)
Where mh
=0.153kg/sec
Cph =3.318kj/kg°c
Tco =320°c
=270°c
= 3045924w
Q =U* A* LMTD
A =Q/ (U*LMTD)
(29005*69.87) = 150.1m2
=3.14*.01905*6.689*360
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= 144.040m2 Actual area =144.040m2
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CONCLUSION
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A heat exchanger that works well in
design .
CHAPTER-11
REFERENCES
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1. Heat and Mass Trans.fer-R.K.Raj put
Rathore
kundwar
6. www.hocl.com
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