HEAT EXCHANGERS CONFIGURATIONS

&
DESIGN CRITERIA

1
Heat Exchangers
 DEFINITION OF HEAT EXCHANGER

Heat Exchanger is a piece of Equipment built for

Efficient heat transfer between a hot and cold
Process Streams.

3
 HEAT EXCHANGERS NOMENCLATURE

• Feed Preheat Train Exchanger

• Water Cooler
• Condenser
• Re-boiler
• Inter Cooler
• After Cooler
• Waste Heat Steam Generator
• Boiler Feed Water Heater
• Air Cooler

4
 HEAT EXCHANGERS NOMENCLATURE

• 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.
• Heater: One stream a process fluid and the other
stream a hot utility, such as steam or hot oil
• Condenser: One stream a condensing vapor and
the other stream a cold utility, such as cooling
water or air.
5
 HEAT EXCHANGERS NOMENCLATURE
Contd.
• 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 (steam
or hot oil) or a process stream.
6
 IMPORTANCE OF HEAT EXCHANGER

Crude Oil
Furnace
Heat Distillation /
Water
Exchangers Vis-breaking /
Coolers Cracking etc.
Products

Steam Generators

Water
Lube Oil Compressor, After
Turbines Coolers
Lube Oil

7
 Principles in Heat Exchanger Operation

The amount of heat transfer in the Heat Exchanger is

affected by:

• Temperature difference (∆t) between the two fluids.

This difference should be sufficiently high to
exchange more heat.

• Contact time between the two fluids: Longer the

time of contact, more heat will be transferred. In
practice this time is availed by the shell baffles / tube
passes and flow pattern ( counter / co-current flow)

8
 Principles in Heat Exchanger Operation
• Surface area of contact: Number / size of tubes is a
design factor in determining the surface area.
• Small tubes provide more area than big ones e.g. 15
tubes of one inch size occupy the space of a single 6
inch tube. The length being the same, they provide 2.5
times the area of the 6 inch tube.
• Scale formation is a major problem affecting the rate
of heat transfer. Scale forming fluids are allowed to
flow inside the tubes for the ease of cleaning.
• Viscous fluids are made to flow in the shell side

9
 Principles in Heat Exchanger Operation

• Tube leak is the major problem in heat exchangers

operation.
• Pressure drop is a strong indicating symptom of
tube leak. In fluids of different colors, change in
color is another reliable indicator.
• Technology of gamma rays inspection is also
applied in detecting tubes leak.
• The flows of the heating (or cooling) fluid, control the
target temperature. Flow Control Valve and bypass
with a valve is used for this purpose

10
 Applications of Heat Exchangers

Heat exchangers are widely used in:

• Chemical / Processing Industry

• Refineries / Petrochemical Industries

• Refrigeration & Air conditioning

• Space heating

• Electricity generation

11
 Basic Criteria for Selection of HE

• Process Specifications
• Service conditions of the Plant, Resistance to
corrosion by the Process
• Maintenance, permission to cleaning and
replacement of components
• Cost- Effectiveness
• Site requirements, lifting & servicing
capabilities

12
Factors affecting Heat Transfer in Exchangers

• Temperature difference

• Surface Area of Heat Exchanger

• Thickness of the tube walls

• Overall heat transfer coefficient

• Conductivity of the Material

13
 Heat Transfer Equation

Q = Cp × m × ΔT
= Cp x m x (T2 – T1)

Where,
Q = Heat supplied / Heat received
m = mass of the Fluid
Cp = Specific heat capacity and
ΔT = (T2 – T1) = Change in temperature

14
 HEAT EXCHANGER - CLASSIFICATION
A - TRANSFER PROCESS Direct Contact
Indirect Contact

B - FLOW ARRANGEMENT Parallel Flow

Counter Flow

Cross Flow

C - GEOMETRY OF CONSTRUCTION Tubular

Plate Type

Extended Surface
 CLASSIFICATION BASED ON GEOMETRY

DOUBLE PIPE FIXED TUBE

TUBULAR. SHELL & TUBE FLOATING HEAD

SPIRAL TUBE U - TUBE

HE
GASKETED
PLATE TYPE.
WELDED

TUBE FINNED
EXTENDED SURFACE.
PLATE FINNED
16
 CLASSIFICATION BY SERVICE

Heat Exchangers are classified into four

categories based on their Service.
• 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)
17
TWO PHASE HE (CONDENSER)

18
TWO PHASE HE (RE-BOILER)

19
RE-BOILER

20
Air-Cooled Heat Exchangers
 TYPES OF HEAT EXCHANGERS

• Shell & Tube Heat Exchanger

• Plate Heat Exchanger

• Plate & Shell Heat Exchanger

22
 SHELL & TUBE HEAT EXCHANGER

• 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.

23
 HEAT EXCHANGER PARTS

Channel Cover Shell Cover

Floating Head Cover
Baffle

Shell

Channel Fixed Tube Sheet Floating Tube Sheet

24
 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

25
 PLATE HEAT EXCHANGER

Metallic Plate Rubber Gasket

Hot Stream

Cold Stream

26
 PLATE HEAT EXCHANGER
• SALIENT FEATURES & ADVANTAGES:

- Compact Design
- Used Where highest purity is required
- Heat Exchanging Capabilities can be Easily Enhanced

• DISADVANTAGES:

- Expensive Design
- Maximum pressure limits to 25 bar.
- Maximum temperature limits to 1700C.
- Costly and Difficult Maintenance
- Several Joints, and hence more Chances of Joint Failure
27
PLATE HEAT EXCHANGER

28
PARTS OF PLATE HEAT EXCHANGER

29
 SHELL & 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 &

 By service

30
SHELL & TUBE HEAT EXCHANGER

31
 CLASSIFICATION BY CONSTRUCTION

It may be classified into three categories.

• Fixed-tube sheet heat exchanger
• U-tube heat exchanger
• Floating-head heat exchanger

32
 FIXED-TUBE SHEET HEAT EXCHANGER

• Fixed-tube sheet heat exchanger has straight

tubes secured at both ends to tube sheets
welded to the shell.
• Construction may have removable channel
covers, bonnet type channel cover.
• Tube-bundle is not removable.
• Applications - Non-fouling Fluids at Shell Side
- Fluids with no Permissible Leakage
33
 FIXED-TUBE SHEET HEAT EXCHANGER

Bonnet
Bonnet Stationary
Support Stationary (Stationary
(Stationary Tubesheet
Bracket Tubesheet Head)
Head)

34
 FIXED-TUBE SHEET HEAT EXCHANGER

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

35
 FIXED-TUBE SHEET HEAT EXCHANGER

Disadvantages:
• Outside of the tube can not be cleaned mechanically
as the bundle can not be removed from the shell.

• Shell Side is not accessible for cleaning or inspection

and due to this shell side fluid should be clean.

• Expansion Joint is Required to Relive Thermal

Stresses

36
 U-TUBE HEAT EXCHANGER
• As name implies, 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.

37
 U-TUBE HEAT EXCHANGER
- Tubes secured at one end (with single tube sheet)
- Tube-Bundle is Removable
- Fouling Fluids at Shell Side
- Large Temperature Difference b/w Shell & Tube Side Fluids
Gasket Shell

Tubesheet
 U-TUBE HEAT EXCHANGER

Advantages:
• Permits Tube Bundle to expand or contract
according to the differential stress set up due
to freeness at one end.
• Tube-Bundle can be removed easily for
Cleaning or Inspection
• No thermal Stress Generation
• Less Expensive

39
 U-TUBE HEAT EXCHANGER

Disadvantages:
• Inside of the tube cannot be cleaned effectively.
• Tube Replacement is Difficult (except Outer
Tubes).
• These Exchangers should not be used for services
which have dirty fluid inside the tubes.
• Refinery Services usually have dirty streams on
both Tube and Shell side and therefore U-tube
heat exchangers are not generally used in oil
Refineries .
40
 FLOATING-HEAD HEAT EXCHANGER

• Floating-head heat Exchanger is one where one tube

sheet is fixed relative to the shell and other is free to
float within the shell.

41
 FLOATING-HEAD HEAT EXCHANGER
Advantages:
• 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.
• No thermal Stress Generation
• Floating-head exchanger has the most versatile
construction. 42
 FLOATING-HEAD HEAT EXCHANGER

Disadvantages:
• 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.
• Cannot be used where leakage is not tolerated.
Applications:
• Fouling Fluids at Both Side.
• Large temp. difference b/w Shell & Tube side
Fluids. 43
Typical Parts and connections shown in the
Figures are summarized below.
Fixed-tube Heat Exchanger
U-tube Heat Exchanger
Floating-head Heat Exchanger
COMPONENT OF S & T HEAT EXCHANGER

The principal components of an S & T Heat

Exchanger are:
• Shell and Shell cover
• Tubes
• Channel and Channel cover
• Tube sheet
• Baffles
• Floating head cover
• Nozzles
48
COMPONENT OF S & T HEAT EXCHANGER
The other components are:
• Tie-rods and spacers
• Pass partition plates
• Impingement plate
• Longitudinal baffles
• Sealing strips, sliding strips
• Supports and foundation
49
 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.

50
 HEAT EXCHANGER 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

51
 HEAT EXCHANGER TUBES

• 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).

52
 HEAT EXCHANGER TUBES

• 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, Haste-alloys and
Tantalum.
53
 TUBE SHEET

• 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 is a tube sheet
fixed or welded to the shell.

54
 TUBE SHEET

Welded tube to tube sheet joints are usually

employed 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.
55
 TUBE SHEET

• 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.

56
TUBE SHEET

57
 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.
• 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.
58
 BAFFLES

• SALIENT FEATURES:
- Used to support Tubes
- Creates turbulence (hence enhance heat transfer)
- Increases Stay Time of Fluid

• DISADVANTAGES:
- Increases Pressure Drop
- Creates Operational Problem
- Creates Stagnant Point for Mud/Dirt

59
 CHOICE OF FLUIDS

• Higher pressure fluids through tubes as small

diameter can withstand higher pressure
• Corrosive fluids in tubes. Scope for higher
metallurgy at low cost in the tube side
• Dirty stock in (straight) tubes since it is easy to
clean but not through U-bundles.
• High Viscosity causes high pressure drop, shell
side is preferred.

80
 FLUIDS IN TUBE SIDE

• Cooling water
• More Corrosive
• More Fouling
• More Viscous
• Under high pressure
• Hotter fluid
• Lesser Flowrate
• Likely to deposit salt, coke, sediment etc.

81
 THERMAL DATA SHEET OF HEAT EXCHANGER

Heat Exchanger Thermal Specification Sheet is divided

into three Parts –

 General information of Heat Exchangers

 Performance of Heat Exchangers

 Construction of heat Exchangers

85
 THERMAL DESIGN SOFTWARE

Thermal Design of Heat Exchangers is done by -

• HTRI (Heat Transfer Research Institute) Software,

USA

86
 MECHANICAL DESIGN

Detailed calculations are carried out to

determine the dimensions of various
components such as Tube, flanges, shell,
channel, Baffle plate, floating head, etc. and a
complete bill of materials and engineering
drawings such as bundles assembly and setting
plan drawings are generated.

87
 EXCHANGER DESIGN PARAMETERS

• Material Selection
• Thickness Calculations - Shell, Channel, Tube Sheet
• No. of Shell Passes
• Velocity of the Fluid
• Pressure Drop
• Tube Pattern
• Consideration of Fluids through Tubes
• Easy Maintenance - Tube size, U - Tube, Cover plate
header, Fluid choice

88
 DESIGN CRITERIA

• 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

89
 DESIGN CRITERIA
Tube Size : 1. 3/4” x 14 BWG x 20 ft mm (Refinery-1)
(19.05 mm OD x 2.11 mm x 6096 mm)
2. 25 mm OD x 2.5 mm Thick x 6000 m

- Smaller Dia tubes are compact and least expensive

- Given shell Dia, ¾” tube will have 15% more area than 1” tube

Tube Material :
1. Carbon Steel - ASTM A179 upto 250oC
2. Alloy Steel - ASTM A 199 T5 above 250oC
3. Stainless Steel - ASTM A268 Tp 405/410
(above 250o C & Corrosive) A213 Tp 316, 321, 347
4. Brass Tubes - ASTM B111 Water Service

90
 DESIGN CRITERIA

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

91
 DESIGN CRITERIA

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.

92
 DESIGN CRITERIA

Cont.

• Velocity:
In general very high velocity lead to erosion.
 For liquid- minimum recommended velocity in
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

93
 DESIGN CRITERIA

Velocity is directly proportional to heat transfer coefficient

but erosion and material limits keep the velocity low.

VELOCITY Min / Max

• Tube side for process liquids - 3 / 6 ft/sec

• Tube side for cooling water - 5 / 6 ft/sec
• Shell side liquid - 2 / 5 ft/sec
• Vapor - 20 / 250 ft/sec

94
 DESIGN CRITERIA

Pressure Drop:

Typical pressure drops:

Tube side - 5 – 8 psi

Shell side - 3 - 5 psi

• Pressure drop requirements are low, avoid

using four or more tube passes as this will
drastically increase your pressure drop

95
 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.

96
 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

97
 HEAT EXCHANGER-MATERIAL SELECTION

• Review operating conditions

• Strength Requirement
• Elevated Temperature Properties
• Corrosion Resistance
• Standardization - To have low Inventory
• Fabricability – Initial Manufacture & Repair

98
 MECHANICAL DESIGN SOFTWARES

PV-Elite & Microprotocol Softwares are

generally used Worldwide.

Microprotocol is by EU Research, France.

PV-Elite is originally from COADE Holdings Inc.

which is taken over by Intergraph, USA

99
Thank You…

100
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