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Heat Exchangers, Strainers and Seperators
Heat Exchangers, Strainers and Seperators
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%20EXCHANGERS,STRAINERS.htm
HEAT EXCHANGERS, STRAINERS AND SEPERATORS
HEAT EXCHANGERS:
A heat exchanger is a device for transferring heat from one fluid to
another, such that fluids are kept separated. They are widely used in
refrigeration, air-conditioning, industrial heating, power production or
chemical and petrochemical industries in various processing. A radiator in
a car is a heat exchanger in which hot radiator fluid is cooled by the flow
of air over the radiator surface.
Broadly heat exchangers may be classified according
A) Their make type
1) Shell & Tube type
2) Plate type
3) Finned tube type
B) flow arrangements:
1) Parallel flow,
2) Counter flow or cross flow,
C) type of heat exchangers tubes
1) straight tube
2) U-tube
D) Type of tube sheets:
1) floating tube type
2) fixed tube and
E) Number of passes
1) one pass
2) Multy-pass
F) Flow of liquids
1) Single flow
2) Split flow or divided flow.
The two fluid in heat exchanger may be both liquid or one liquid and
another gas or both gas. For better efficiency heat exchangers are
designed to maximize the surface area between the two fluids, contact
period of two fluid while minimizing resistance to their flow. A typical heat
exchanger is the shell and tube heat exchanger in which one fluid flow in
the tube and the other fluid flows in the shell.
A heat exchanger may be used to cool the discharge gas of
compressor as an interstage cooler or to produce steam by the waste heat
of flue gas of process as a waste heat boiler. Condenser or cooler are
basically heat exchangers but name has been given as per the service.
The international standards for Heat Exchangers is TEMA (Tubular
Exchanger Manufacturer Association) which define the type of the heat
exchangers, design factor, fabrication etc.
In General a heat exchanger consists of following parts:
i)
Shell
ii)
Tubes or Tube bundle
iii)
Tube sheets
iv)
Baffle Plates
v)
Tie-rods
vi)
Inlet Nozzle
vii)
Outlet Nozzle
viii)
End channel covers Plenums
ix)
Floating head etc.
TEMA NOMENECLATURE:
It is recommended by TEMA that heat exchanger size and type be
designated by number and letters. And shall be a part of equipment name
plate. TEMA nomenclature represents not only the type of heat exchanger
but also give size of exchangers. e.g. dia of the tube sheet, length of tubes
etc. Examples of TEMA nomenclature:
SIZE 23-192 TYPE AES means split ring floating head exchangers with
removel channel and cover ,single pass shell size 23 inside diameter with
192 long tube.
SIZE 17-192 TYPE CEN means fixed tube heat exchanger having stationery
and rear heads integral with tube sheets, Single pass shell, 17 inside
diameter with 192 inch (16, ft) tube length
SIZE 19-84 TYPE BGV mean U- tube exchanger with bonnet type
stationery head split flow shell 19 inside dia with 84 tube length.
The material of the heat exchanger may be carbon steel, stainless steel
or alloy steel and the material of the tubes may be carbon steel alloy
steel, stainless steel, copper etc. depending up on the service condition
requirement. Heat exchanger design depend upon fluid parameters
(corrosive or non corrosive) temperature, pressure, or phase of fluid etc.
There are certain compact design which may be used where area
constrain is observed.
Heat exchanger tubes are of different types. For better efficiency, finned
tubes can be used. Finning of tubes also help in making heat exchangers
compact. Finning may be inside of the tube or out side or both side,
depending on the service requirement.
During fabrication, all NDT are followed as per QAPs but as a safety
measure
and
reliability
improvement,
all
heat
exchangers
are
specify design,
3) Bucket type
4) Conical etc.
Y- TYPE STRAINERS:
These look as if horizontal Y shape fitting has been installed in the
pipeline. These strainers have lower dirt holding capacity than basket type
strainer. On application where significant amount of debris are expected a
blow down valve can usually be fitted in the strainer cap, which enables
the strainers to use the pressure of the fluid to be cleaned and without
having the system shutdown. Y-type strainer in horizontal steam or gas
lines should be installed in such a manner so that the pocket is in the
horizontal plane. This stops water collecting in the pocket helping to
prevent water droplets being carried over which can cause erosion and
affect heat transfer processes.
On liquid system however the pocket should point vertically down wards,
this ensures that the removed debris is not drawn back into the upstream
pipeline during low flow conditions. Installation of Y-type strainer is not
possible in case of vertical line upward flow but in vertical line down ward
flow it is possible and very effective.
BASKET TYPE STRAINER:These strainers are more suitable where flow is very high. These can be
installed in horizontal pipe line or vertical line in down ward flow only. In
case of steam line if basket or bucket type strainer are installed, a
significant amount of condensate may be formed and which shall be
removed by drain plug or steam trap. Basket type strainer has a greater
free straining area and also the pressure drop across the strainer is less
then Y-type strainer.
CONICAL STRAINERS:
These are conical in shape and can be installed in either direction, over
the cone or under the cone. These strainers can be installed in any
pipelines and are preferred in case of gases where flow is very high.
Because they helps in stream lining the inlet flow to any machine.
Disadvantage is that, a spool piece is required to be opened for cleaning
of this type of strainers.
c) NOTCH WIRE SCREEN:The notch wire element is manufactured by wrapping specially treated
thin stainless steel wire(special cross section wire called notch wire)
around the cylindrical filter frame. It has a simple structure and robust
form, allowing very accurate setting of the filtering passage size. In
addition, because the element is not subject to corrosion or deterioration,
and impurities adhered to the element can easily be eliminated by
backwashing or air blowing, the element requires no replacement and has
a semi-permanent service life. Because of its high reliability . Notch wire
mesh provides more area of opening per unit area of the mesh as
compared to woven mesh
FILTER :- Very fine strainers are called filters. Strainer are generally used
in process fluids just before the rotary machines while Filter remove very
fine particles from the fluid and are used in lubrication system and or fuel
gas and instrument air system. Generally a strainer is installed in the
suction of a pump or compressor where as filter are installed in discharge
of the pumps of lubrication system etc.
SEPARATORS: To separate two different fluids from each other while in flow and thus to
move unwanted or damaging suspended fluid from gas stream separator
are used. In case of steam water droplets are separated from steam , in
case of oil mixed gas oil is separated from the gas or condensate is
separated from the gas. Separator are must required to separate out
these suspended fluid from the gaseous stream as these fluid contents
may damage the equipment/system (condensate in case of compressor)
or may be re-used later (incase of oil which is reused again). In process
also it become desirable to separate out oil from the gas as oil may
damage the catalyst.
These separators are basically liquid traps.
In case of steam there is always water droplets, which eventually
gravitate towards the bottom of the pipe, which affect the system as
below:
Water droplets works as an extremely effective barrier for heat
transfer .
Water droplets traveling at high velocity will erode the pipe , valve
seat or fittings and also increase the corrosion rate if any.
The selection of separator depends upon the velocity of the fluid, size of
the pipeline, pressure drop allowable and the type of the fluid. By proper
selection of separator maximum efficiency can be achieved. Operating
pressure and flow rate of the fluid are also a criteria for selection of
separators.