Heat Exchangers

Submitted to: Mr. Atif

Arsalan Khalid
TRAINEE ENGINEER | ENGINEERING SERVICE DEPARTMENT

Table of Contents
Introduction ....................................................................................................................................................1 Classification of Heat Exchangers ...................................................................................................................1 Shell and Tube Heat Exchangers .....................................................................................................................2 Types and Components of S&T Heat Exchangers ...........................................................................................2 Types of S&T Heat Exchangers....................................................................................................................3 Components of S&T Heat Exchangers ........................................................................................................5 Nomenclature .................................................................................................................................................5 Stationary Head Nomenclature ..................................................................................................................5 Rear Head Nomenclature ...........................................................................................................................6 Codes and Standards ......................................................................................................................................7 Working of Heat Exchanger ............................................................................................................................7 Site Visit ..........................................................................................................................................................8 Equipment Tag ................................................................................................................................................8 Data Sheet.......................................................................................................................................................9 Metallurgy.....................................................................................................................................................10 References ....................................................................................................................................................10

Heat Exchangers
Introduction
A heat exchanger is a device that is used to transfer thermal energy (enthalpy) between two or more fluids, between a solid surface and a fluid, or between solid particulates and a fluid, at different temperatures and in thermal contact. In heat exchangers, there are usually no external heat and work interactions. Typical applications involve heating or cooling of a fluid stream of concern and evaporation or condensation of single- or multicomponent fluid streams. In other applications, the objective may be to recover or reject heat, or sterilize, pasteurize, fractionate, distill, concentrate, crystallize, or control a process fluid. In a few heat exchangers, the fluids exchanging heat are in direct contact. In most heat exchangers, heat transfer between fluids takes place through a separating wall or into and out of a wall in a transient manner. In many heat exchangers, the fluids are separated by a heat transfer surface, and ideally they not mix or leak. A heat exchanger consists of heat transfer elements such as a core or matrix containing the heat transfer surface, and fluid distribution elements such as headers, manifolds, tanks, inlet and outlet nozzles or pipes, or seals. Usually, there are no moving parts in a heat exchanger; however, there are exceptions, such as a rotary regenerative exchanger (in which the matrix is mechanically driven to rotate at some design speed) or a scraped surface heat exchanger.

Classification of Heat Exchangers

A variety of heat exchangers are used in industrial processes and systems. A brief grading of most of these heat exchangers is shown below by using some classification schemes. Heat exchangers are classified according to transfer processes, number of fluids, degree of surface compactness, construction features, flow arrangements, and heat transfer mechanisms in the Figure 1.

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Figure 1: Classifications of Heat Exchangers (Shah, 1981)

Shell and Tube Heat Exchangers

Shell and tube heat exchangers are of major concern in this assignment and will be discussed in detail in the rest of the assignment. Shell-and-tube heat exchangers are fabricated with round tubes mounted in cylindrical shells with their axes coaxial with the shell axis. The differences between the many variations of this basic type of heat exchanger lie mainly in their construction features and the provisions made for handling differential thermal expansion between tubes and shell [1]. There are various design considerations to be taken into account such as routing of fluids (shell or tube), pressure drop especially in the case of increasing number of baffles and tube diameter and adjusting the area with the suitability of the exchanger to conduct the heat required to heat or cool a fluid with another one.

Types and Components of S&T Heat Exchangers

Shell and tube heat exchangers are classified mainly on basis of their construction. A variety of different internal constructions are used in shell-and-tube exchangers, depending on the desired heat transfer and pressure drop performance and the methods employed to reduce thermal stresses, to prevent leakages, to provide for ease of cleaning, to contain operating pressures and temperatures, to control corrosion, to Page | 2

accommodate highly asymmetric flows, and so on. Most common types of Shell and tube heat exchangers are given below with representation and nomenclature/standard terminology of their basic parts.

Types of S&T Heat Exchangers

Figure 2: Floating Head Design

Figure 3: Fixed Tube Sheet Design (01 shell pass and 01 tube pass)

Figure 4: Fixed Tube Sheet Design (01 shell pass and 02 tube passes)

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Figure 5: U-Tube Design

Figure 6): Kettle Type Design (With Floating Head)

Figure 7: Divided Flow type (With Externally Sealed Floating Head)

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Components of S&T Heat Exchangers

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Stationary Head Channel Stationary head bonnet Stationary head flange channel or bonnet Channel cover Stationary head nozzle Stationary tube sheets Tubes Shell Shell cover Shell flange stationary head end Shell flange rear end Shell nozzle Shell cover flange Expansion joint Floating tube shell Floating head cover Floating head flange Floating head backing device Split shear ring Slip on backing flange 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Floating head cover external Floating tube sheet skirt Packing box Packing Packing gland Lantern rings Tie rods and spacers Transverse baffles and support plates Impingement plates Longitudinal baffle Pass partition Vent connection Drain connection Instrument connection Support saddle Lifting lug Support bracket Weir Liquid level connection Floating head support

Nomenclature
Shell-and-tube exchangers are classified and constructed in accordance with the widely used TEMA (Tubular Exchanger Manufacturers Association) standards (TEMA, 1999), DIN and other standards in Europe and elsewhere, and ASME (American Society of Mechanical Engineers) boiler and pressure vessel codes. TEMA has developed a notation system to designate major types of shell-and-tube exchangers. In this system, each exchanger is designated by a three-letter combination, the first letter indicating the frontend head type, the second the shell type, and the third the rear-end head type. These are identified in figure given below. Some common shell-and-tube exchangers are AES, BEM, AEP, CFU, AKT, and AJW.

Stationary Head Nomenclature

Type A: features a removable channel with removable cover plate. It is used with fixed tube sheet, U-tube, removable bundle exchanger designs. This is the most stationary head type. Type B: features a removable channel with an integral cover. It is used with fixed tube sheet, U-tube and removable bundle exchanger design. Type C & N: the channel with a removable cover is integral with the tube sheet. Type C is attached to the shell by a flanged joint and is used for U-tube and removable bundles. Type N is integral with shell and is used with fixed tube sheet designs. The use of type N heads with U-tube and removable bundles is not recommended since the channel is integral with the tube bundle, which complicates bundle maintenance. Type D: This is special high pressure head used when tube side design pressure exceeds approximately 6900 kPa guage. The channel and tube sheet are integral forged construction. The channel cover is applied by special High pressure bolting. Page | 5

Figure 8: TEMA Nomenclature (1999)

Rear Head Nomenclature

Type L: Similar in construction to the Type A stationary head. It is used with fixed tube sheet exchanger when mechanical cleaning of the tubes is required. Type M: Similar in construction to Type B stationary head. It is used with fixed tube heat exchangers. Type N: Similar in construction to Type N stationary head. It is used with fixed tube heat exchangers. Page | 6

Type P: Called an outside packed floating head. The design features an integral rear channel and tube sheet with a packed joint seal (stuffing box) against the shell. It is normally used due to the tendency of packed joints to leak. It should be used with hydrocarbons or toxic fluids on the shell side. Type S: Constructed with a floating tube sheet contained between a split ring and a tube sheet cover. (The shell cover must be removable design to allow access to the floating head assembly) Type T: Constructed with a floating tube sheet bolted directly to the tube sheet cover. It can be used with either an integral or removable shell cover. Type U: This head type designates that the tube bundle is constructed of U-tubes. Type W: A floating head design that utilizes a packed joint to separate the tube side and shell side fluids. The packing is compressed against the tube sheet by the sell rear cover bolted joint. It should never be used with hydrocarbons or toxic fluids on either side.

Codes and Standards

API 660 and TEMA B, C and R covers the shell and tube heat exchangers. Standards used during MCR heat exchanger designs are API 660, TEMA R and ASME VIII Div. 1. According to API 660, 6th Edition other codes and standards used as part of API 660 for heat exchangers are: ASME B1.201: Pipe threads, general purpose (inch) ASME B16.5: Pipe flanges and flange fittings (NPS to NPS 24) ASME B16.11: Forged fittings, socket welding and threaded ASME B16.47: Large disc steel flanges (NPS 26 to NPS 60) ASME B 46.1: Surface Texture (Surface roughness, waviness etc.) Boiler and Pressure Vessel code Section II: Materials Section V: No- destructive testing techniques Section VIII Div. I: Rules for construction of pressure vessels Section IX: Welding and Brazing qualifications AWS D1.1: Structural steel welding code TEMA B C and R

Working of Heat Exchanger

S&T heat exchanger typically involves two flowing fluids separated by a solid wall. Heat is first transferred from the hot fluid to the wall by convection, through the wall by conduction, and from the wall to the cold fluid again by convection. Any radiation effects are usually included in the convection heat transfer coefficients. The mechanism of heat transfer is represented in the given figure.

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Figure 9: Heat Exchange through Wall of Heat Exchanger

Site Visit
Area 100 was visited to observe the S&T heat exchangers. Following heat exchangers were observed.

Tag No. 100-E9

100-E11 A/B 100-E12 A/B 100-E13 100-E14 100-E15 100-E16 100-E17 A/B 100-E18 A/B 100-E19 A/B 100-E20 A/B 100-E21 A/B

Description Desalted Crude Cold Diesel Product Exchanger Desalted Crude HVGO Exchanger No.1 Desalted Crude Circulating Diesel Exchanger Desalted Crude HVGO Exchanger No.2 Desalted Crude Hot Diesel Product Exchanger Flashed Crude HVGO Exchanger No. 3 Flashed Crude Circulating Diesel Exchanger No. 3 Flashed Crude/Cold Vacuum Bottoms Exchanger Flashed Crude HVGO Exchanger No.4 Flashed Crude Hot Vacuum Bottoms Exchanger Crude Column Trim Condenser Demineralized Water Diesel Product Exchanger

S/S Fluid Diesel Product

HVGO Circulating Diesel HVGO Diesel Product HVGO Circulating Diesel Cold Vacuum Bottoms HVGO Hot Vacuum Bottoms Crude Column Vapor Diesel Product

T/S Fluid Desalted Crude

Desalted Crude Crude Desalted Crude Desalted Crude Flashed Crude Flashed Crude Flashed Crude Flashed Crude Flashed Crude Cooling Water Demineralized Water

Equipment Tag
The equipment tag of shell and tube heat exchanger contained following information. 1. 3. 5. 7. 9. 11. Tag Number Surface Area Design Temperature (Shell and Tube) Radiographic Exam Pneumatic Test Bundle Weight 2. 4. 6. 8. 10. 12. Code: ASME VIII Division I Design Pressure (Shell & Tube) PWHT (Shell and Tube) Hydrostatic Test Unit Weight Year built Page | 8

Data Sheet
Data Sheet of 100-E21 A/B is given below

100-E21 A/B
Service Manufacture size Manufacture Type Sensible Heat (Kcal/hr) Latent Heat (Kcal/hr) Total Heat (Kcal/hr) Number of tubes Tube Length (m) Tube type Tube OD (mm) Tube Thickness (mm) Pitch (mm) Shell ID LMTD Corrected (Deg C) Overall Rate Design (Kcal/hr m2 C) Crude Column Trim Condenser 750 x 6096 AES 5.35 e 6 N/A 5.35 e 6 516 6.096 Plain 19.05 1.65 75 25.4 39.8 379 Shell Side Fluid Circulated Hydrocarbon 1.42 wt% S Allowable Pressure Drop (kg/cm2 (g)) 1.05 Calculated Pressure Drop (kg/cm2 (g)) 0.62 Specific Heat 0.547 Specific Gravity 0.761 No of Passes 01 Viscosity CP 0.684 Operating Pressure 11.2 Thermal Conductivity (kcal/hr mol deg C) 0.094 Velocity (m/s) 0.5 Film rate (hr m2 Deg C/ kCal) 0.0006 Inlet Shell Side Total Fluid MW (kg/hr) 110360 Liquid MW (kg/hr) 110360 Operating Temperature (Deg C) 153 Shell Outlet Operating Temperature (Deg C) 56 Tube Side Fluid Circulated Demineralized Water Allowable Pressure Drop (kg/cm2 g) 1.41 Calculated Pressure Drop (kg/cm2 g) 0.4 No of Passes 04 Operating Pressure 12.6 Velocity (m/s) 0.84 Tube Side Inlet Total fluid MW (kg/hr) 75100 Water MW (kg/hr) 71500 Operating Temperature (Deg C) 21 Tube Side Outlet Operating Temperature (Deg C) 92 Page | 9

Metallurgy
Common materials used for tubes are carbon steel, red brass 45% ars copper, 4-6% chrome % moly steel 80-20 Cu-Ni, 70-30 Cu-Ni, Monel, Copper 99.9% Cu Nickel Aluminum, Stainless steel AISI type 302 & 304.

References
API 660, 6th edition, Shell and Tube Heat Exchangers TEMA, 1999, Standards of TEMA, 8th ed., Tubular Exchanger Manufacturers Association, New York. Bejan and A. D. Kraus, Heat Transfer Handbook, 2003. Shah, R. K., 1981, Classification of heat exchangers, in Heat Exchangers Donald Q. Kern, Heat Transfer, 1982.

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