Heat Exchangers M

PDEC
INDIAN OIL CORPORATION LTD

PROCESS DESIGN ENGINEERING CELL(PDEC)
HEAT EXCHANGERS DESIGN

&
MANUFACTURING FEATURES
BY
M. BALA
1
CONTENT PDEC
• DEFINITION OF HEAT EXCHANGERS
• TYPES OF HEAT EXCHANGERS
• CLASSIFICATION OF SHEEL AND TUBE HEAT

EXCHANGERS
• DIFFERENT TYPES OF HEAT TRANSFER

EQUIPMENTS
2
CONTENT PDEC
• COMPONENTS OF SHELL AND TUBE HEAT

EXCHANGERS
• NOMENCLATURE OF HEAT EXCHANGERS
• CONSTRUCTION OF HEAT EXCHANGERS
3
CONTENT PDEC
• CODES/ STANDARDS
• DESIGN OF HEAT EXCHANGERS
• MATERIAL IDENTIFICATION CHART
• SELECTION OF HEAT EXCHANGERS TYPES
4
CONTENT PDEC
• THERMAL DATA SHEET OF HEAT EXCHANGERS
• MECHANICAL DATA SHEET OF HEAT

EXCHANGERS
• MANUFACTURING FEATURE
• MAINTENANCE OF HEAT EXCHANGERS
5
HEAT EXCHANGERS DESIGN PDEC
DEFINITION OF HEAT EXCHANGER:

A heat exchanger is a piece of equipment built for
efficient heat transfer between a hot process
stream and a cold process stream.
6
TYPES OF HEAT EXCHANGERS:
• Shell & Tube heat exchanger
• Plate heat exchanger
• Plate & Shell heat exchanger
7
SHELL AND TUBE HEAT EXCHANGER
Shell & tube heat exchangers consist of a

series of tubes & cylindrical shell. One set
of these tubes contains the fluid that must
be either heated or cooled. The second
fluid runs over the tubes i.e inside the shell
that are being heated or cooled. A set of
tubes is called the tube bundle.(as shown
in Fig). 8
SHELL AND TUBE HEAT EXCHANGER
9
COMPLETE HEAT EXCHANGER PDEC
10
PLATE HEAT EXCHANGER
It is composed of multiple, thin, slightly

separated plates that have very large surface
areas and fluid flow passages for heat transfer.
• Much higher heat transfer co-efficient
• Lower cost, low space requirement
11
PLATE HEAT EXCHANGERS PDEC
12
PLATE AND SHELL HEAT EXCHANGERS
• It is combines with plate heat exchanger and

shell & tube heat exchanger technologies.
• High heat transfer, high pressure, high
operating temperature
• Compact in size
• Low fouling
13
PLATE AND SHELL HEAT EXCHANGERS
14
TYPE OF SHELL AND TUBE HEAT EXCHANGERS

• Shell and Tube Heat Exchangers (STHEs) are the
most widely and commonly used unfired heat
transfer equipment in the chemical process
industries.
• Shell and tube heat exchanger may be classified
By construction and
By service
15
HEAT EXCHANGERS NOMENCLATURE:
An STHE is divided into three parts mainly:
• The front head

• The shell and
• The rear head
16
TEMA DESIGNATIONS FOR SHELL-AND-TUBE. HEAT
EXCHANGERS PDEC
17
HEAT EXCHANGERS NOMENCLATURE:
• There are five front head types: A, B, C, D and

N.
• There are eight rear head types: L, M, N, P, S, T,

V, and W which corresponding in practice to
only three general construction types, namely
fixed tube sheet, U-tube and floating head.
18
Cont:
• Rear head ‘L’ is identical to a front head ‘A’

and rear head ‘M’ is identical to a front head
‘B’ while N is the same nomenclature.
• There are seven types of shell depending on

fluid flows through a shell - E, F, G, H, J, K
and X.
19
• CLASSIFICATION BY CONSTRUCTION
It may be classified into three categories.
• Fixed-tube sheet heat exchanger
• U-tube heat exchanger
• Floating- head heat exchanger
20
FIXED-TUBE SHEET HEAT EXCHANGER
• A fixed-tube sheet heat exchanger has

straight tubes secured at both ends to tube
sheets welded to the shell.
• The construction may have removable

channel covers (e.g. AEL), bonnet –type
channel covers (e.g. BEM) or integral tube
sheets (e.g. NEN)
21

Bonnet
Bonnet Stationary
Support Stationary (Stationary
(Stationary Tubesheet
Bracket Tubesheet Head)
Head)
22
Advantages of this exchangers

• The main advantage of a fixed-tube sheet
construction is low cost as it has the simplest
construction.
• Permits mechanical cleaning of the inside of
the tubes as these are accessible after
removal of the channel cover or bonnet.
23
• No leakage from the shell side fluid as there

are no flanged joint.
Disadvantages of this exchangers
• The outside of the tube can not be cleaned
mechanically as the bundle can not be
removed from the shell.
• Due to this shell side fluid should be clean
24
U-TUBE HEAT EXCHANGER

• As name implies, the tubes of a U-tube heat
exchanger are bent in the shape of a U. There
is only one tube sheet in a U-tube heat
exchanger.
25

Advantages of this exchangers
• It permits the tube bundle to expand or
contract according to the differential stress set
up due to free at one end.
• It permits the outside of the tubes cleaning as

the tube bundle can be removed.
26

Disadvantages of this exchangers
• The inside of the tube cannot be cleaned
effectively.
• This exchangers should not be used for

services which have dirty fluid inside the
tubes.
27
• It places a very severe limitation on U-tube

heat exchangers for refinery services, which
usually have dirty streams on both the tube
side and shell side. This is primarily the reason
why U- tube heat exchangers are not generally
used in oil refineries .
28
FLOATING- HEAD HEAT EXCHANGER

• A Floating-heat exchanger is one where
one tube sheet is fixed relative to the shell
and the other is free to float within the
shell.
29

•Advantages of the exchangers
This type of heat exchanger permits free

expansion of the tube bundle
It permits cleaning of both the inside and

outside of the tubes.
It is used for services where both the shell side

and tube side fluids are dirty.
30

Floating head exchanger is the most versatile
construction.
•Disadvantages of this exchangers

It is more costlier than Fixed tube & U- tube
exchangers due to:
 More components in this construction
 Shell diameter is larger than floating tube
sheet.
31
Various types of floating head construction are:
• Pull through with backing device:TEMA type S

• Pull through: TEMA type T
• Outside- packed stuffing – box: TEMA type P
• Outside-packed lantern ring: TEMA type W
32
• PULL THROUGH WITH BACKING DEVICE: TEMA type S
Most commonly used type in the chemical

processing industries.
The floating head cover is secured against the
floating tube sheet by bolting it to an ingenious
device called split backing ring.
The floating head closure is located beyond the
end of the shell and contained by a shell cover of
a larger diameter.
33
Cont.
For dismantling the heat exchanger, the shell
cover is removed first, then the split backing ring
and finally the floating head cover after which the
tube bundle can be removed from the stationary
end.
For assembling the heat exchangers, the reverse

order is followed.
34
PULL THROUGH WITH BACKING DEVICE: TEMA type S
35
Pull through: TEMA type T

• The floating head cover is bolted directly to
the floating tube sheet so that a split backing
ring is not required.
• The advantage of this type construction is
that the tube bundle may be removed from
the shell without removing either the shell
or floating head cover.
36
Pull through: TEMA type T
• It is generally used for kettle re-boilers

having a dirty heating medium where u-tube
cannot be used.
• The shell diameter is the largest in this type
of construction since floating head tube
sheet with cover has to be removed through
the shell. Hence, the cost is the highest in
this type of construction.
37
• Pull through: TEMA type T
Rear tubad end Shell Stationary

Head end
16
21
6 15
3
10
38
OUTSIDE-PACKED STUFFING–BOX:TEMA TYPE P

• In this construction, the shell side fluid is sealed
by ring of packing compressed within a stuffing-
box by a follower ring.
• This construction is prone to leakage. Due to this,
its usage is limited to shell side services, which
are:
 Non-hazardous and non-toxic services
 Moderate pressure and temperature (40
kg/cm² and 300ºc).
39
OUTSIDE- PACKED STUFFING – BOX: TEMA TYPE P
25
24
26 27
29
28
40
OUTSIDE-PACKED LANTERN RING: TEMA TYPE W
• The shell side and tube side fluids are sealed by

separate ring of packing or O-ring and separated by a
lantern ring provided with weep holes. Hence any
leakage will be the outside.
• The width of the tube sheet necessarily has to be

sufficient to accommodate the two packing rings and
the lantern ring, plus the expansion margin.
41
OUTSIDE-PACKED LANTERN RING: TEMA TYPE W

• This design is limited to 9.9 kg/cm² and 204ºc.
27
26
24
3
30
42
CLASSIFICATION BY SERVICE
It may be classified into four categories.
• Single phase (both shell side and tube side)
• Condensing (one side condensing and other
single phase)
• Vaporizing ( one side vaporizing and the other
single phase)
• Condensing/vaporizing (one side condensing and
the other vaporizing)
43
PDEC
DIFFERENT TYPES OF HEAT TRANSFER EQUIPMENTS
• Heat Exchanger: both side single phase process

streams (that is not an utility).
• Cooler: One stream a process fluid and the other

stream a cold utility, such as cooling water or air.
• .
44
PDEC
Cont.
• Heater: One stream a process fluid and the other
stream a hot utility, such as stream or hot oil
• Condenser: One stream a condensing vapor and

the other stream a cold utility, such as cooling
water or air.
45
PDEC
Cont.
• Chiller: One stream a process fluid being
condensed at sub-zero temperature and the other
stream a boiling refrigerant or process stream
(evidently cryogenic).
• Vaporizer: One stream a vaporizing liquid and the
other a gas or a liquid.
• Re-boiler: One stream a bottom stream from a

distillation column and other a hot utility (stream
or hot oil) or a process stream. 46
RE-BOILER PDEC
47
PDEC
COMPONENT OF STHEs :
The principal components of an STHE are:
• Shell and Shell cover
• Tubes
• Channel and Channel cover

48
PDEC
• Tube sheet
• Baffles
• Floating head cover
• Nozzles
49
PDEC
The other components are,
• Tie-rods and spacers,
• Pass partition plates,
• Impingement plate,
50
PDEC
• Longitudinal baffles,
• Sealing strips, sliding strips,
• Supports and foundation
51
VARIOUS PARTS OF HEAT EXCHANGER PDEC
52
VARIOUS PARTS OF HEAT EXCHANGER PDEC
1. Stationary Head-Channel
17. Floating Head Cover Flange
2. Stationary Head-Bonnet 18. Floating Head Backing Device
3. Stationary Head Flange-channel Or Bonnet 19. Split Shear Ring
4. Channel Cover 20. Slip-On Backing Flang
5. Stationary Head Nozzle 21. Floating Head Cover
6. Stationary Tubesheet 22. Floating Tubesheet Skirt
7. Tubes 23. Packing Box
8. Shell 24. Packing
9. Shell Cover 25. Packing Gland

26. Lantern Ring
10. Shell Flange-Stationary Head End
27. Tierods and Spacers
11. Shell Flange-Rear Head End
12. Shell Nozzle
28. Transverse baffles or Support Plates
13. Shell Cover Flange
29. Impingement Plate
14. Expansion Joint 30. Longitudinal Baffle
15. Floating Tubesheet 31. Pass Partition
16. Floating Head Cover 32. Vent Connection
53
PDEC
SHELL AND SHELL COVER:

• The shell is cylinder in which tubes are contained
and serves to contain the shell side flowing stream
and forms the outer casing of the tube bundle.
TUBE BUNDLE:
• The tube bundle is the heart of the shell and tube
unit and comprises tubes, tube sheets, baffles,
floating head cover, split ring. Tie rods,
impingement plate, baffle, longitudinal baffle and
sealing/sliding strips.
54
PDEC
TUBES:
• Tubes are most vital component of the heat

exchangers.
• Tubes are two types, namely a) plain or bare

and b) finned – external or internal
• Plain tubes are most common ones which are

generally used in refineries
55
PDEC
Cont.
• Tubes are usually defined by outer dia (OD)
and wall thickness (or BWG- Birmingham Wire
Gauge).
• Wall thickness can be either minimum wall

(when there is no under-tolerance, but only
over tolerance), or average wall thickness
(when there is both under tolerance and over
tolerance).
56
PDEC
Cont.
• The usual practice is to order tubes with
minimum wall thickness for carbon steel and
low alloy steel tubes and with average wall
thickness for non-ferrous and high-alloy steel
tubes.
• Material of construction of tubes are- carbon
steel, low and high alloy steels, special
stainless steels, Admiralty brass and bronze,
alloys of copper and nickel, Hastealloys and
Tantalum. 57
PDEC
TUBE SHEETS:
• The ends of the tubes fit into a common sheet
and are expanded against or welded to the shell
to form a pressure tight seal which separates
fluid in the shell and that in the tubes.
Tube sheet are two types
• Fixed/stationary tube sheet – A tube sheet fixed

or welded to the shell.
58
PDEC
Welded tube to tube sheet joints are

usuallyemployed for severe condition such as
high pressure (say, in excess of 80 kg/cm²) or
when handling toxic or inflammable fluids
where leakage is not permitted.
Floating tube sheet:

• A tube sheet which can move to allow for
expansion or contraction of the tubes relative
to the shell.
59
PDEC
• Tube sheet thickness can vary from 25 mm for

low-pressure low shell dia. to 300 mm for high
pressure & large shell
• Depending on the severity of the situation, tubes
are either expanded into grooves in the tube sheet
or welded to theme to tube sheet
Baffles:
• It serve to support the tubes as well as to impart a
sufficiently shell side velocity to yield a satisfactory
heat transfer co-efficient.
60
PDEC
• Baffles are held securely in place by a

combination of tie rods and spacers.
• The length of spacers is equal to the baffle

spacing.
• The outside diameter of the baffle has to be

less than the inside diameter of the shell to
permit insertion of the tube bundle into the
shell and removal of the bundle from the shell.
61
PDEC
LONGITUDINAL BAFFLES:
• A plate which is placed transversely along the

centre line of the shell and is employed to
divide the shell into two or more
compartments is called longitudinal baffle.
• A single longitudinal baffle from one tube

sheet to just sort of the other tube sheet
produce on ‘F’ shell i.e. a shell with two shell
passes.
62
PDEC
SLIDING AND SEALING STRIPS:
• A pair of sliding strips is provided at the bottom

of floating head tube bundles for their
insertion and removal to and from the shell.
• A sufficient number of sealing strips is required

to be inserted in the gap between the shell and
outer most tubes in floating head tube bundles
to minimize leakage of the shell
63
PDEC
IMPINGEMENT PLATE:
• The inlet nozzle is provided with a plate
which is used to protect the uppermost
tubes located just below the shell side inlet
nozzle against direct impingement by the
shell side fluid is called an impingement
plate.
CHANNEL, CHANNEL COVER & PASS
PARTITION PLATES:
• Channel is the inlet and outlet chambers for
the fluids flowing through the tubes. 64
PDEC
• A channel may either be of a bonnet const.

where a dished end is welded to channel barrel
or a flanged channel cover.
• Pass partition plates are the plate in the
channel which make the fluid in the tubes flow
through one set of tubes and back through
another set. They fit tightly into grooves in the
tube sheet and channel cover in order to
eliminate the possibility of leakage of the tube
side fluid from one pass to the next.
65
PASS PARTITION ARRANGEMENT FOR TUBE PASSES PDEC
66
PDEC
CODES/STANDARDS:
• API 660 - Shell & tube heat exchangers for
general refinery services.
• ASME Section VIII – Pressure Vessels for

Shell thickness cal., Welding & Testing
requirements.
• TEMA(Tubular Exchanger Manufacturers

Association) for design of STHEs
67
PDEC
TEMA:
There are three classes of TEMA;
• Class-R Refinery Service
• Class-B Chemical Process service
• Class-C General service
LIMITATION OF TEMA:
• Inside diameter of shell is 2540 mm
• A design pressure of 211 kg/cm2
68
PDEC
BASIC FORMULA:
The basic formula for heat transfer is,

Q = A* U*△T
Where,
Q = Total heat to be transferred, Kcal/hr
A = Required effective heat exchanger surface,
based on the tube O.D , m2
U= Overall heat transfer co-efficient,Kcal/hr-m2-c
69
PDEC
Cont.
△T = effective mean temperature difference, OC
For exchangers where the flow of the hot and cold

fluids is true counter or concurrent, △T is equal to
the log mean temperature difference (LMTD)
In most commercial exchangers, the use of shell
baffles and multiple tube passes causes the flow to
be partially counter current and
70
Cont.
Where, LMTD =
Ln (
△
△
partially concurrent flow. For this mixed flow △T
is obtained by applying a correction factor (F) to
the calculated LMTD for a counter current flow
arrangement i.e.
△T (effective) = LMTD * F ( F= < 1.0)
h -
h /
c
c )
PDEC
71
PDEC
Cont.
Where,
△Th = T1 - t2
△Tc = T2 - t1
T1 = Inlet temp. of hot fluid

T2 = Outlet temp. of hot fluid
t 1 = Inlet temp. of cold fluid
t 2 = Outlet temp. of cold fluid
72
PDEC
Cont.
The value of correction factor “F” is obtained from
TEMA chart. “F” is plotted as a function of “P” and
“R” . Where” and “R”
P = Temp. effectiveness or efficiency of exch.
= (△t of cold fluid) / (△t of hot & cold fluid inlet
temp.)
t2 - t1
P=
T1 - t1
73
PDEC
Cont.
Where,
R = Heat capacity rate ratio.
= wc / Wc
T1 - T2
R =
t2 - t1
74
PDEC
BASIS OF DESIGN PRESSURE:

• Maximum pump shut of pressure, or
• 25 psi or 10% greater than the maximum
operating pressure in PSIG
BASIS OF DESIGN TEMPERATURE:
• The minimum design temp is normally set a

25oC above the maximum operating temp at the
exchanger
75
PDEC
DESIGN OF STHEs:
The design of shell and tube heat exchangers

comprises two distinct activities
are:
• Thermal design and
• Mechanical design
76
PDEC
Thermal design:
• In thermal design, the heat exchangers is sized,

which means that all the principal construction
parameters such as shell type and diameter,
number of tubes, tube OD and thickness, tube
length, tube pitch, number of tube passes,
baffle spacing & cut and nozzles sizes are
determined.
77
PDEC
Basic aims of a thermal designer are:

1.Produce a thermal design that has a low overall
cost.
• Overall cost = initial cost + operating cost
• Initial cost is evidently the fixed cost or first
cost of the heat exchangers
• Operating cost = pumping cost + maintenance
cost + down time cost
78
PDEC
Cont.:
• Maintenance cost= periodically cleaning cost +
anti - foulant cost + any repair or replace. Cost.
2. Utilize allowable pressure drop as fully as
possible.
• Higher the velocity of the fluid higher will be
the heat transfer co-efficient.
• Higher heat transfer co-efficient will be higher
pressure drop.
79
PDEC
Cont.:
• Higher heat transfer co-efficient will tend to
reduce first cost of the exchangers.
• Higher pressure drop will tend to increase the
operating cost of the exchangers
• Thus a very important goal for a good thermal
design is the best utilization of the allowable
pressure drop
80
PDEC
REQUIRED DATA FOR THERMAL DESIGN :
Process dept. have to furnish the following data for

thermal design of heat exchangers:
• Name of the fluids

• Flow rate of the fluids
• Inlet & outlet temperature of the fluids
• Operating pressure of the fluids
81
PDEC
Cont.
• Allowable pressure drop
Generally 0.5 to 0.7 kg/cm2 per shell for liquid
0.05 to 0.02 kg/cm2 per shell for gases
• Fouling refers- accumulation and deposition of
living organisms and certain non-living materials
on the surface
• Properties of fluids like – Specific gravity/ density,
thermal conductivity, viscosity and specific heat.
82
PDEC
Cont.
• Heat release profile for two phase flow – it is a
plot of heat duty and weight fraction vapor versus
temperature and is an essential part of the
process data sheet.
• Heat exchanged i.e. heat duty
83
PDEC
Cont.
• Selection of heat exchanger type i.e Fixed tube, U-
tube or Floating head tube exchangers (i.e AES,
BEM )etc.
• Placement of Fluids
 Generally low flow rate fluid is placed on the
shell side .This facilitates provision of adequate
turbulence by increasing number of baffles
84
PDEC
Cont.
Cooling water which is likely to deposit scales is
generally placed on tube side for facilitating
mechanical cleaning of tubes from inside
 In general highly befouling fluids that need
frequent mechanical cleaning of heat exchangers
are usually placed on tube side
 Highly corrosive fluids are preferably placed on
tube side
85
PDEC
Cont.
 Fluids with very high operating pressure are
preferably placed on tube side
• Line sizes: Generally line size match with nozzle
sizes
• Preferred tube size:
OD: Commonly used OD 19.05/ 25.4 mm
Tube thick.: Commonly used thk.2 / 2.5 mm
Length: Commonly used length 6000 / 9000 mm
86
PDEC
Cont.
• Maximum shell diameter

As per TEMA ID is 2540 mm
As per engineering practice,
For floating & U-tube exchangers: Shell ID 1400-
1500 mm
For fixed tube heat exchanger: No limitation
87
PDEC
Cont.
• Corrosion allowance
Tube: As per TEMA no corrosion allowance is

applied in tube
Shell: Depends on services and materials of
construction. Generally 1.5 to 3 mm is used
depending on materials.
88
PDEC
Cont.
• Velocity –In-general very high velocity lead to

erosion.
 For liquid- minimum recommended velocity in s
tube side is 0.9 m/s while maximum is 2.4 m/s.
Shell side velocity is from 0.6 t0 1.5 m/s
For gases – maximum tube side velocity is 35 m/s
89
PDEC
Cont.
• Type of shell
As per TEMA, there are seven types of shells like
E, F, G, H, J, K & X.
• Tube lay out pattern

There are 4 types of tube lay out pattern.
90
PDEC
Triangular- Not Used when mechanically cleaning is required.

Rotated Triangular- Not Used when mechanically cleaning is required
91
PDEC
Square- When mechanically cleaning is required

Rotated square- When mechanically cleaning is
required
92
PDEC
• Tube Pitch; center to center distance between

two adjacent tubes.
For triangular & rotated triangular pattern
tube pitch is 1.25 times the tube OD
For square or rotated square pattern

tube pitch is generally (OD+6mm)
93
SELECTION OF HEAT EXC.TYPE BASIS ON SERVICES PDEC
Final decision on exchanger type depends on

many factors but the table given below is only
for guide line
Shell side fluid Tube side fluid Type of exchanger
Clean Dirty Clean Dirty
Yes - Yes - Fixed tube sheet or U-tube with triangular pitch
Yes - - Yes Fixed tube sheet or floating head with triangular

pitch
- Yes Yes - U-tube or floating head with square pitch
- Yes - Yes Floating head with square pitch
94
PDEC
THERMAL DESIGN OF HEAT EXCHANGERS IS DONE

BY
• HTRI (Heat Transfer Research Institute) Soft ware,

USA
95
PDEC
THERMAL DATA SHEET OF HEAT

EXCHANGER:
• Heat exchanger thermal specification
sheet is divided into three parts,
General information of exchangers
Performance of exchangers
Construction of exchangers
96
PDEC
• MECHANICAL DESIGN:
Detailed calculations are carried out to

determine the dimensions of various
components such as tube sheets,girth flanges,
shell , shell barrel, channel, channel barrel,Baffle
plate, floating head dish, etc and a complete bill
of materials and engineering drawings such as
bundles assembly and setting plan drawings are
generated.
97
Baffles: PDEC
Generally there are two types of baffles

• Plate type - Single segmental
- Double segmental
- Triple segmental
98
PLATE TYPE BAFFLES: PDEC
99
PDEC
ROD TYPE BAFFLE-

Entire heat transfer area is effective
Tube bundle is vibration free
No stagnation of flow, uniform flow
Pressure drop minimum
100
ROD TYPE BAFFLE: PDEC
101
PDEC
BAFFLE SPACING:
• Center to center line distance between

adjacent baffles is called baffle spacing
• Minimum spacing as per TEMA is one fifth

of the shell ID or 51 mm whichever is
greater.
102
PDEC
BAFFLE SPACING:
• For example if shell inside diameter = 1000

m Then 1/5th = 1000/5 = 200 mm
• So spacing should be 200 mm
• Maximum spacing is usually the shell ID
103
PDEC
BAFFLE CUT:
• It is the segment opening heights
expressed as a percentage of the shell
inside diameter . Baffle cuts are :
• Horizontal- This is used for single pass
shell for minimizing the accumulation of
deposit at the bottom.
104
PDEC
BAFFLE CUT:
• Vertical - This is used for two pass shell
for ease of fabrication and bundle
assembly, as well as for condenser.
• Recommended baffle cut is from 20% to

35% 105
BAFFLE PLATE THICKNESS : PDEC
Baffle or support plate thickness should be

as per below table (R-4.41 of TEMA)
Shell ID Plate thickness
Unsupported tube length between central baffles
610 mm & Over 610 - Over 914 - Over 1219 Over
under 914 mm 1219 mm - 1524mm 1525mm
152 – 356 3.2 4.8 6.4 9.5 9.5
381 - 711 4.8 6.4 9.5 9.5 12.7
735 - 965 6.4 7.5 9.5 12.7 15.9
991 - 1524 6.4 9.5 12.7 15.9 15.9
1549 - 2540 9.5 12.7 15.9 19.1 19.1
106
TIE ROD AND SPACERS: PDEC
Tie rod and spacers shall be provided to retain

all baffles and tube support plates securely in
position.
Number and size of the tie rods will be as per
below table (R-4.71 of TEMA)
Nominal shell diameter Tie rod diameter in mm Minimum number of tie
in mm rod
152 - 381 9.5 4
406 – 686 9.5 6
711 – 838 12.7 6
864 – 1219 12.7 8
1245 – 1524 12.7 10
1549 - 2540 15.9 12
107
Material Identification chart: PDEC
Description of
Carbon steel Alloy steel Stainless Steel
parts
Shell SA516Gr60/70 SA387GR5CL2 SA240Gr316
Shell cover barrel SA516Gr60/70 SA387GR5CL2 SA240Gr316
Shell cover bonnet SA516Gr60/70 SA387GR5CL2 SA240Gr316
Channel SA516Gr60/70 SA387GR5CL2 SA240Gr316
Channel cover SA105 SA182GrF5 SA182Gr316
Tubes SA179 SA213GrT5 SA213Gr316
Tubes sheet SA266Gr.2 SA336GrF5 SA240Gr316
Baffles SA516Gr60/70 SA387 Gr5CL2 SA240Gr316
Floating Head Dish SA266Gr.2 SA336GrF5 SA336Gr316
Girth Flanges SA266Gr.2 SA336GrF5 SA336Gr316
108
Material Identification chart: PDEC
Description of
Carbon steel Alloy steel Stainless Steel
parts
Nozzles Neck SA106GrB SA335GrP5 SA312Gr316
Nozzles Flanges SA105 SA182GrF5 SA182Gr316
PAD SA516Gr60/70 SA387GR5CL2 SA240Gr316
Backing Ring SA105 SA336GrF5 SA336Gr316
Tie Rods SA516Gr60/70 SA387GR5CL2 SA240Gr316
Partition Plate SA516Gr60/70 SA387GR5CL2 SA240Gr316
Impingement plate SA516Gr60/70 SA387GR5CL2 SA240Gr316
Sealing strips SA516Gr60/70 SA387GR5CL2 SA240Gr316
Spacers SA179 SA213GrT5 SA213Gr316
Saddle plate SA516Gr60/70 SA387GR5CL2 SA240Gr311
109
PDEC
MECHANICAL DATA SHEET OF EXCHANGER:

• This is required for procurement of heat
exchangers.
110
PDEC
• DESIGN SOFTWARE:
• PV ELITE and Microprotol software are being

used worldwide
• Microprotol By EU Research, France
• PV- Elite by COADE taken over by Intergraph,

USA
111
MANUFACTURING FEATURES PDEC
DRAWINGS AND ASME CODE DATA REPORT:

• Drawings for approval and change
The manufacturer shall submit for purchaser’s
approval three(3) prints of an outline drawing
showing nozzle sizes and locations, overall
dimensions, support and weight.
 It is anticipated that a reasonable number of
minor drawing changes may be required at that
time.
112
Cont.
Any changes may cause additional expense
chargeable to the purchaser.
Purchaser’s approval of drawings does not relieve
the manufacturer of resposibility for compliance
with the standard and applicable ASME code
requirements.
The manufacturer shall not make any changes on
the approved drawings without express agreement
of the purchaser.
113
Cont.
Any changes may cause additional expense
chargeable to the purchaser.
Purchaser’s approval of drawings does not relieve
the manufacturer of responsibility for compliance
with the standard and applicable ASME code
requirements.
The manufacturer shall not make any changes on
the approved drawings without express agreement
of the purchaser.
114
Cont.
Shop detail drawings are for internal use by the
fabricator, it may be furnished to the purchaser
upon request.
• Drawings for record

After approval of drawings manufacturer furnished
3 set of drawings along with all documents to the
purchaser
115
• Proprietary rights to drawings

The drawings and the design indicated by the
manufacturer are to be considered the property of
the manufacturer and are not to be used or
reproduced without his permission, except by the
purchaser for his own internal use.
• ASME code data reports
After completion of fabrication and inspection of
ASME code stamped exchangers, the manufa. shall
furnish 3 set of ASME data report.
116
INSPECTION:
There are two yepes of inspection:
• Manufacturer’s Inspection
• Purchaser’s Inspection
• Manufacturer’s Inspection
Inspection and testing of units will be provided by
the manufacturer unless otherwise specified.
117
The manufacturer shall carry out the inspection

required by the ASME code and also inspection by
state and local codes .
• Purchaser’s Inspection
The purchaser shall have the right to make
inspection during fabrication and to witness any
test.
Inspection by the purshaser shall not relieve the
manufacturer of his responsibilities. 118
PREPARATION FOR SHIPMENT:

• Cleaning
Internal and external surfaces are to be free from
loose scale and other foreign material that is readily
removable by hand or power brushing
• Draining
Water, oil or other liquids used for cleaning or
hydro-static testing are to be drained from all units
before shipment. 119
• Flange protection
All exposed machined contact surfaces shall be
coated with a removable rust preventative.
All threaded connections are to be suitably plugged.
• Damage protection
The exchangers and any spare parts are to be
suitably protected to prevent damage during
shipment.
120
GUARANTEES:
It may be given on the basis of
• Performance and
• Defective parts
• Performance Guarantee
The manufacturer shall guarantee thermal
performance and mechanical design of a heat
exchanger, when operated at the design conditions
specified by the purchaser in his order.
121
Cont.
This guarantee shall extend for a period of twelve

months after shipping date.
The thermal guarantee shall not be applicable to

exchangers where the thermal perfomance rating
was made by the purhaser.
122
• Defective parts Guarantee
The manufacturer shall repair or replace any parts

proven defective within the guarantee period.
Finished materials and accessories purchased from
other manufacturers, including tubes are warranted
only to the extent of the original manufacturer’s
warranty to the heat exchanger.
123
PDEC
MANUFACTURES OF HEAT EXCHANGER:
• M/s Aero-therm Products
• M/s Hindustan Radiators
• M/s Unique Chemo-plant Equipments
• M/s Larsen & Toubro

124
PDEC
MANUFACTURES OF HEAT EXCHANGER:
• M/s Hindustan Dorr Oliver Ltd
• M/s Godrej
• M/s Precision Engineering.
• M/s Universal Heat Exchangers

125
PDEC
MAINT. OF HEAT EXCHANGERS
126
ROUTINE MAINTENANCE PDEC
OPERATIONAL PROBLEMS
• Decline in heat transfer efficiency / high
pressure drop
• Scaling, fouling, choking, etc.,
• Internal Leak
Causing contamination between shell
and tube fluids
127
ROUTINE MAINTENANCE PDEC
OPERATIONAL PROBLEMS
• Gasket Leaks
Due to thermal shock during start-
up, shutdowns & Upsets
• Tube Leaks
Tube failure due to fatigue, ageing
& corrosion
BLINDING THE EQUIPMENTS
128
PASSIVATION PDEC
• Why ?
(During a shutdown, in the presence of
air and liquid water, often dew point
water, the sulfides convert to polythionic
acid which causes inter-granular Stress
Corrosion Cracking to Austenitic steels)
• Materials prone for SCC
(Austenitic SS tube bundles - SS 304,
SS310, SS316, SS321, SS347)
129
PASSIVATION PDEC
• When ?
Before Opening of the equipments
• Solution
Soaked with a solution of DM Water, Sodium
Carbonate (2%) and Sodium Nitrate (0.5%) for
about 8 hours.
130
PDEC
• Opening the covers of heat exchangers

• Removing of bundle
Bundle Extractor or Puller
131
EXCHANGER CLEANING PDEC
• Chemical Cleaning
 Shell - Fixed Tube Sheet Bundle
 Vacuum Condensers, Ejector Condensers,
Reboilers
 0.5% concentration HCl with inhibitor
circulation for 8 hours
 Hot water wash
 Branded chemicals
 Online by wash water circulation
132
PDEC
• Kero -bath soaking

Crude vacuum, Asphalt services
• Hydroblasting (For Tube exteriors)
Water jet at a pressure of 300 - 600 Kg/Sq.cm
(Up to 35000 psi / 2500 bar)
133
Hydro-blasting (For Tube exteriors) PDEC
Before Cleaning After Cleaning
134
Hydro-lancing (For Tube interiors) PDEC
Manual Operation Power Lancing

135
Hydro-lancing (For Tube interiors) PDEC
Before Cleaning After cleaning

136
PDEC
• Gasket Replacement
A gasket is a compressible material, or
combination of materials, which when
clamped between two stationary members
prevents the passage of the media across
those members.
• Gasket Selection
Tem. of the media to be contained,
Corrosive nature of the application and
Criticality of the application
137
PDEC
• GASKET CLASSIFICATION
CAF (Compressed asbestos fiber)
250 deg. C, 30 bar,
Water, steam and for non-critical applications
138
PDEC
IJA (Iron Jacketed Asbestos)
High Temperature applications
Sheet Metal - SS, Brass, Monel , Al, In-conel
Filler - Asbestos, PTEF, Grafoil
139
PDEC
Spiral Wound Gasket (SPWD)
(SPWD) with Asbestos filled & Inner Ring (13mm)
& Outer Nose (4 mm width) 260 – 650 C
Winding - SS 410, 304, 316, Monel, Inconel
Filler - CAF(360oC), PTFE(260oC),
Graphite(550oC), Ceramic(650oC)
140
PDEC
TUBE BUNDLE RETUBING

• More number of tubes plugged
• Not possible to clear the tubes
• Scaling & poor heat transfer
• After average life of the bundle
• Frequent failures
141
PDEC
TUBE BUNDLE RETUBING

• Full or Partial
• Where
At Bundle Shop or at Position
142
PDEC
THANK YOU
143

Heat Exchangers M

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PDEC

INDIAN OIL CORPORATION LTD

HEAT EXCHANGERS DESIGN

• DEFINITION OF HEAT EXCHANGERS

• TYPES OF HEAT EXCHANGERS

• CLASSIFICATION OF SHEEL AND TUBE HEAT

• DIFFERENT TYPES OF HEAT TRANSFER

• COMPONENTS OF SHELL AND TUBE HEAT

• NOMENCLATURE OF HEAT EXCHANGERS

• CONSTRUCTION OF HEAT EXCHANGERS

• DESIGN OF HEAT EXCHANGERS

• MATERIAL IDENTIFICATION CHART

• SELECTION OF HEAT EXCHANGERS TYPES

• THERMAL DATA SHEET OF HEAT EXCHANGERS

• MECHANICAL DATA SHEET OF HEAT

• MAINTENANCE OF HEAT EXCHANGERS

DEFINITION OF HEAT EXCHANGER:

TYPES OF HEAT EXCHANGERS:

• Shell & Tube heat exchanger

• Plate heat exchanger

• Plate & Shell heat exchanger

SHELL AND TUBE HEAT EXCHANGER

Shell & tube heat exchangers consist of a

SHELL AND TUBE HEAT EXCHANGER

PLATE HEAT EXCHANGER

It is composed of multiple, thin, slightly

PLATE AND SHELL HEAT EXCHANGERS

• It is combines with plate heat exchanger and

PLATE AND SHELL HEAT EXCHANGERS

TYPE OF SHELL AND TUBE HEAT EXCHANGERS

HEAT EXCHANGERS NOMENCLATURE:

An STHE is divided into three parts mainly:

• The front head

HEAT EXCHANGERS NOMENCLATURE:

• There are five front head types: A, B, C, D and

• There are eight rear head types: L, M, N, P, S, T,

• Rear head ‘L’ is identical to a front head ‘A’

• There are seven types of shell depending on

• Fixed-tube sheet heat exchanger

• U-tube heat exchanger

• Floating- head heat exchanger

FIXED-TUBE SHEET HEAT EXCHANGER

• A fixed-tube sheet heat exchanger has

• The construction may have removable

FIXED-TUBE SHEET HEAT EXCHANGER

FIXED-TUBE SHEET HEAT EXCHANGER

Advantages of this exchangers

FIXED-TUBE SHEET HEAT EXCHANGER

• No leakage from the shell side fluid as there

U-TUBE HEAT EXCHANGER

U-TUBE HEAT EXCHANGER

• It permits the outside of the tubes cleaning as

U-TUBE HEAT EXCHANGER

• This exchangers should not be used for

U-TUBE HEAT EXCHANGER

• It places a very severe limitation on U-tube

FLOATING- HEAD HEAT EXCHANGER

FLOATING- HEAD HEAT EXCHANGER

This type of heat exchanger permits free

It permits cleaning of both the inside and

It is used for services where both the shell side

FLOATING- HEAD HEAT EXCHANGER

•Disadvantages of this exchangers