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Pi Ups 1004
Pi Ups 1004
Pi Ups 1004
: 29040-PI-UPS-1004
PIPING STUDY
Rev. : R0
HEAT EXCHANGER PIPING
Uhde India Limited Page : 1
CONTENTS
Page
1.0 Introduction 4
2.0 Location 4
Applicable Revision:
Prepared: Checked: Approved:
4 HEP4 TYPES OF EXCHANGER : SHELL & TUBE, PLATE TYPE & AIR
COOLER EXCHANGER
5 HEP5 AIR COOLER EXCHANGER CONSTRUCTION
1.0 INTRODUCTION
Heat Exchangers are widely used equipments in the chemical, petrochemical and refinery type of
plant. The control of heat within a plant operation is done by direct heat application in a furnace, or
by heat exchange in a shell and tube exchanger / plate heat exchanger. Types of heat exchanger
may be Shell and Tube, Aircooled (Fin-Fan), Plate type or Coil type(spiral).
1.1 Various process duties of heat exchanger have an effect on the layout aspects viz.
1.2 - Fixed tube exchangers are used when the temperature differences between shell side and tube
side fluid are small.
- Floating head or U-type exchangers are used where there is a significant temperature difference.
- Kettle -type reboilers are used for evaporation in case of limiting pressure drop, otherwise vertical
reboilers are used for evaporation.
- Plate heat exchangers are generally used in low-pressure, low temperature applications. The
plate exchanger occupies less space than shell and tube exchanger for equivalent heat
exchanger surface.
- Aircoolers are used for overhead condensers of column and consist of fin-tube bundles with a
header box to each end, having inlet on top of header-box at one end and outlet on bottom of
header box at the other end.
1.3 Various types of heat exchangers with application in schematic flow diagram are illustrated in the
Fig.HEL1, HEP2, HEP3, HEP4 & HEP5.
1.4 For single pass arrangement of air-cooler exchangers, inlet nozzles are mounted on the top of the
header box and the outlet nozzles are located at the opposite end and mounted on the bottom of the
header box. For double pass arrangement, the inlet and outlet nozzles are located at the same end.
2.0 LOCATION
Exchangers should be located close to the major equipment with which it is associated in PFD /
P&ID. Reboilers are placed next to their respective towers and condensers are placed over reflux
drums. Exchangers between two distant pieces of process equipment should be placed at optimal
points in relationship to piperacks.
Most exchangers are to be located at grade level with elevations to have a clearance of 1m above
Finished Ground Level (FGL). Elevated exchangers may be necessary to fulfill the NPSH
requirement of a downstream centrifugal pump.
In case of large numbers of heat exchangers, they are grouped in one or more category to save pipe
work, structural work, provision of lifting and maintenance facilities, platform requirement etc. Paired
or grouped exchnagers shall be spaced to allow minimum 450mm preferrably 600mm between the
outside of adjacent channel or bonnet flanges to facilitate access to flange bolts during maintenance.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1004
PIPING STUDY
Rev. : R0
HEAT EXCHANGER PIPING
Uhde India Limited Page : 5
Adequate space shall be provided on either side of paired exchanger and at both ends of grouped
exchanger for control and operator access as illustrated in Fig.HEP9.
Groups of exchangers should be generally located by the alignment of channel nozzles in a vertical
plane so as to present an aesthetic appearance.
The support saddle with elongated holes for provision of thermal expansion are normally located on
the saddle farthest from the channel end but the final location depends on the plant layout and the
stress analysis of the connected piping.
Exchanger piping should be as direct and simple as possible by considering alternatives such as
arranging exchangers side by side / stacking them or reversing flows.
Exchangers are sometimes mounted on structures, process columns and other equipment.
Special arrangements for maintenance and tube cleaning should be provided.
3.1 Horizontal clearance of at least 900mm should be left between exchangers flange to flange or
exchanger flanges and piping. Where space is limited, clearance may be reduced between alternate
exchangers but in no case clearance over insulation between channel flanges to be less than
600mm.
3.2 The channel ends of exchangers should face the local access road for bundle removal and the shell
cover should face the piperack. Pulled out bundles should not extend over main access road.
A typical exchanger arrangement with clearance for access, operation and maintenance is shown in
Fig.HEP7.
Access for tube bundle removal is usually 1.5 times the bundle length.
3.3 Mobile equipment should be used for handling tube bundles and covers at grade level. Expensive
built-in facilities e.g. lifting beams, monorails to be kept at minimum.
3.4 The use of tube-bundle extractor eliminates the need for permanent tube bundle removal structures.
These mechanisms weigh around seven tons and are capable of pull forces about 500,000lbs. The
tube-bundle is held in position by crane and balanced by the extractor's leveling cradle and pulled
and out of its shell with pull rod attachments that use hydraulic force.
3.5 For air-cooled exchangers, platform arrangements must suit maintenance access requirements.
Considerations must be given to fin-tube bundle removal, tube rodding out at header boxes, motor
and fan access.
3.6 Provision of easily removable spool pieces, flanged elbows, break flanges or short pipe runs will be
helpful for maintenance of exchangers.
3.7 Illustrations for exchanger location in unit plot plan alongwith the provisions of operating and
maintenance space, accessibility are shown thru' Fig.HEP6, HEP7, HEP8, HEP9, HEP10, HEP11,
HEP12, HEP13, HEP14, HEP15 & HEP16 as typical cases.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1004
PIPING STUDY
Rev. : R0
HEAT EXCHANGER PIPING
Uhde India Limited Page : 6
Step 2 : Study the P&ID around the heat exchanger and identify the relationship with the connected
equipment viz. column or reactor.
Step 3 : Note the special process (functional) requirement along with the arrangement specific details
with respect to level or height difference from other related equipment like pumps.
Step 4 : Study the nozzle schedule, its position on the equipment and verify with P&ID.
Step 5 : Make a sketch for the relative location and level. Find out the tube cleaning space in case shell
& tube Heat Exchanger as well as the maintenance space of tube bundle length.
Step 6 : Locate the control valve stations both for shell side and tube side fluids.
Step 7 : Decide the flanged joints location for replacement of Heat Exchanger / maintenance facility.
Step 8 : Check, in general, that cooled streams flow downwards and heated streams flow upwards. This
arrangement is mandatory when there is a change of phase, desirable when the streams are
liquid but not important when the streams are gas or vapour or there is no super heating,
super cooling.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1004
PIPING STUDY
Rev. : R0
HEAT EXCHANGER PIPING
Uhde India Limited Page : 7
Step 9 : Check, piping should not foul exchanger removal either in the horizontal direction for bundle-
pulling nor in the vertical for whole exchanger removal.
Step 10: Check, locally mounted PI, TI on equipment or process lines, sight glasses and level indicators
are visible from access aisles and valves are accessible from the aisles.
Step 11: Mark the supports / support arrangement on the piping study.
Step 12: Ensure accessibility / operation facility for all valves as well as the clearance kept are not less
than the recommended minimum requirement.
After all the required information has been collected for the piping design of a heat exchanger, the
first step is to outline clearance and working space in front and around both ends of the exchanger.
These working spaces should be kept clear of any piping and accessories to facilitate channel, shell-
cover and tube-bundle removal as well as maintenance and cleaning.
The free space at the side of horizontal shell can be used for placement of controls.
The piping is elevated from grade to have a clearance of 300mm above the grade level. The piping
connected to channel head nozzles should be furnished with break flanges to facilitate the removal of
the channel head.
Steam lines connecting to a header in the yard can be arranged on either side of the exchanger
centerline without increasing the pipe length.
Cooling-water lines, mostly under ground, should run right under the lined-up channel nozzles of all
coolers.
Access to valve hand wheels and instruments will influence the piping arrangement around heat
exchangers valve handwheels should be accessible from grade and from a convenient accessway.
These accessways should be used for arranging manifolds, control valves and instruments.
Fig. HEP 20, HEP21, HEP22, HEP23, HEP24, HEP25, HEP26, HEP27 & HEP28 illustrates some
typical piping arrangement around shell & tube exchangers.
Piping at spiral and plate exchangers is also arranged to allow opening of covers and removal of
plates.
Controls at the spiral exchanger are located on the ends of the unit, clear of the cover plate swing
area, piping attachment to cover plate nozzles of spiral exchanger will have break flanges.
Controls for plate exchanger are located at the front and one side of the exchanger. The piping is
elevated to have clearance from grade as well as convenience for operation of valves.
Fig.HEP29 and HPE30 illustrates the typical piping arrangements around spiral & plate exchangers.
TRAINING MANUAL- PIPING DOC No. : 29040-PI-UPS-1004
PIPING STUDY
Rev. : R0
HEAT EXCHANGER PIPING
Uhde India Limited Page : 8
Piping for air coolers are not routed over tube banks or fans and should be kept clear of the
designated space for motor maintenance.
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP1
CONDENSER
(AIR COOLER)
AIR
STEAM
SHELL & TUBE
WATER
HEATER
COOLER
EXCHANGER PROCESS
SHELL &
TUBE
REBOILER STEAM
CHILLER REFRIGERANT
SHELL &
TUBE
KETTLE
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP2
1ST FLUID 2ND FLUID SHELL RELIEF VALVE REMOVABLE SHELL 2ND FLUID
ENTERS LEAVES NOZZLE CONNECTION TUBE BUNDLE NOZZLE ENTERS
(COLD) (WARM) (HOT)
SHELL
VENT
REAR
HEAD
DRAIN
DRAIN
DRAIN SADDLE BAFFLE(TYP)
1ST FLUID SADDLE
LEAVES
HEAD NOZZLE
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP3
CHANNEL HEAD
HORIZONTAL BAFFLE
TUBE SIDE FIXED TUBE SHELL SIDE SHELL SUPPORT SHELL FLOATING
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP4
PLATE EXCHANGER
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP5
MOTOTR
OUTLET NOZZLE
SUPPORT CHANNEL
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP6
C COLUMN
L
PLATE EXCHANGER
HIGH PRESSURE
EXCHANGERS
HORIZONTAL REBOILER
C COLUMN
L
KETTLE
VERTICAL REBOILER
C COLUMN
L
C COLUMN
L
SPIRAL
EXCHANGERS PRODUCT COOLERS
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP7
2" MIN.
CLEARANCE 2'-6"
(750)
2" MIN.
PIPERACK
SPACE FOR
ACCESS
PULLING TUBES
2'-6"
(750)
2" MIN.
PIPERACK
CLEARANCE 2'-6"
(750) SPACE FOR
ACCESS
PULLING TUBES
2" MIN.
2'
(2) ADD THICKNESS OF INSULATION FOR EXCHANGER SHELLS AND CONNECTED PIPING TO CLEARANCE AS SHOWN.
(3) PROVIDE ADDITIONAL CLEARANCE TO THE 2'-6"(750) OPERATING SPACE IF VALVE HANDWHEELS AND VALVE
STEMS, etc., PROTRUDE, DEPENDING ON PIPING ARRANGEMENT.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP8
C TOWER
L
- CHANNEL END TO FACE MAINTENANCE ACCESS WAY FOR TUBE BUNDLE REMOVAL.
- PROVISION OF ADEQUATE SPACE FOR BONNET REMOVAL.
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP9
TOWER
DRUM
18"/.450
CONTROL
MINIMUM
SPACE (TYP.)
SINGLE PAIRED
EXCHANGER EXCHANGERS
CONTROL
SPACE (TYP.)
OPERATOR OPERATOR
ACCESS ACCESS
CONTROL
SPACE (TYP.)
OPERATOR OPERATOR
ACCESS ACCESS
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP10
ELBOW NOZZLE
SPACE FRAME
12'-0"/3.600
SAME SERVICE DISSIMILAR SERVICE SAME SERVICE
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP11
18"/.450 MIN.
AUXILIARY ROAD
OR MAINTENANCE
ACCESS WAY
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP12
TUBE BUNDLE
REMOVAL AREA
TOWER ALTERNATIVE
CHANNEL DESIGN
2'/.600 TO 5'/1.500
PLATFORM
REBOILER
HITCH POINTS FOR
COVER REMOVAL
PLATFORM
MAXIMUM
WITHOUT
.900 MIN.
12'-0"/
3.600
3'-0"/
1"/.025 GAP
ADD 1"/.025
PLATFORM SHIM
SUPPORT STEEL
GUIDE
REMOVABLE
CHANNEL EXTRACT
SECTION TUBE-BUNDLE
UN-BOLT
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP13
TUBE BUNDLE
REMOVAL AREA
MINIMUM
4'-0"/1.200
(TYP.) (MAXIMUM)
6'-0"/1.800
LUGS
PLATFORM
18"/.450
MINIMUM 12'-0"/3.600 MAXIMUM
WITHOUT PLATFORM
3'-0"/.900 MINIMUM
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP14
CONTROL
SPACE
(TYP.)
OPERATOR ACCESS
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP15
INDUCED DRAFT
AIR COOLER
MOTOR
MOTOR
7'-0"/2.100 MIN.
(TYP.)
(TYP.)
HEADER BOX
PLATFORM
PIPE RACK
ADDITIONAL PLATFORM
IF LADDER RUN IS
LONGER THAN
30'-0"/9.150
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP16
LADDER TO
MAINTENANCE
PLATFORM (TYP.)
HEADER BOX
PLATFORM (TYP.)
LADDER TO MOTOR
GRADE (TYP.) (TYP.)
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP17
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP18
ELBOW NOZZLES
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP19
AIR COOLERS
C TOWER
L
DOUBLE PASS
OUTLET
LOCATION
REFLUX DRUM
GRAVITY FLOW
ALTERNATIVE
LOCATION
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP20
CL EXCHANGER
ALLOW SPACE
FOR PULLING
TUBES
OBLIQUE OFFSETS IN PIPING SIMILIAR 90°ELBOW
TO THOSE SHOWN. ALLOW EXCHANGERS NOZZLE
TO BE PLACED CLOSER TOGETHER.
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP21
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP22
OPERATOR ACCESS
ACCESS TO FLANGE BOLTS
450
(ALL AROUND)
450
MAINTENANCE ACCESS
600 TO 900
C TOWER
L
PIPE RACK
MAINTENANCE ACCESS
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP23
INTERMEDIATE SUPPORT
REQUIRED FOR PIPING
THAT IS OVER SPANNED
BETWEEN PIPE RACK AND
EXCHANGERS
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP24
THI
COOLING WATER
HOT WATER
CHECK CLEARANCE
WITH FOUNDATIONS
ANTIFREEZE BYPASS
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP25
LEVEL
GAUGE ELEVATION OF
CONDENSATE POT
SET BY PROCESS
CONDITIONS
TRUNNION
SUPPORT
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP26
SYMMETRICAL PIPING
LUGS
INDEPENDENT
STRUCTURE
SUPPORTING REBOILER
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP27
HIGH TEMPERATURE,
HIGH PRESSURE
ALLOY PIPING
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP28
LOCATE PIPING
BENEATH PLATFORM
FOR EASE OF
SUPPORT
COOLING WATER
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP29
COVER PLATE
SWING AREA
REMOVABLE
SPOOL (TYP.)
Rev. : R0
PIPING STUDY
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DWG. NO. : HEP30
CONTROL
VALVE
(TYP.)
CONTROL VALVES
PLAN
ELEVATION
TRAINING MANUAL - PIPING DOC NO. : 29040-PI-UPS-1004
Rev. : R0
PIPING STUDY
Uhde India Limited HEAT EXCHANGER Page :1
DWG. NO. : HEP31
AIR COOLER
AIR COOLER
C TOWER
L