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Analysis of Heat exchangers

Efficient heat exchange comes in various formsAkshay Kr MishraSharda UniversityMECH , 4 YR.

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Types of heat exchanger

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Counter flowCross flowDiagonal flow

Radiator type HXs (RHE)

AIR to WATER heat exchanger.Uses fans to circulate air and cool the fluid inside tubes of HXs.Cooling medium is AIR.Radiator is made via Al alloy.

Working of a radiator type HX

How to Maintain RHEsFeed the oil from inlet only.

Flush clean the radiator with pressurized air once in a week, to maintain proper air flow.

Dont keep any obstacle in front of radiator which may obstruct the air flow.

DAIKIN 90507; TRACTOR PLANT( M/C SHOP)

DAIKIN 80017; TRACTOR PLANT( M/C SHOP)

DSL 50; AXLE PLANT(STEERING KNUCKLE LINE)

HH5C-PLC; AXLE PLANT( STEERING KNUCKLE LINE)

#50604 HELLER MCH300; BKW HX; TRACTOR PLANT( M/C SHOP)

Applications of RHEForced air heating & coolingIndoor & outdoor wood furnaces/stoves/boilersHeat pumpsChilled water coolingPermanent aluminum fin to copper coil bond ensures superior heat transfer properties

Cooling towersHeat withdrawn from water viacontact between thewaterand theair.Heat exchange is b/w air and water and through the evaporation of a small part of the water that needs to be cooled.It allows to cool downto a temperature lower than the ambient temperature, which is an important advantage compared to dry coolers.A regular maintenance will also minimize the risk of legionella.

Cooling tower, utility area

Plate type Hxs (PHE)Constitutes of 2 plates fix frame plate and pressure plate(movable).Pack of corrugated metal plates with portholes for passage of 2 fluids b/w which Heat transfer takes place.These plates are fitted with gasket which seals the inter plate channel and directs the fluids into alt. channels.

Exploded view of plate heat exchanger

Principle of PHEChannels are formed b/w the plates & corner ports are arranged so that the media flows through alt. channels.Heat transferred via plate b/w channels & complete concurrent flow is made for highest possible efficiency.Corrugation of plates provides passage b/w plates, support each plate against adjacent one and enhances the turbulence, resulting in efficient heat transfer.

CHESSISE PHE; AM 10 FM1; TRACTOR PLANT (PAINT SHOP)

Leakage in plate heat exchangerdefects

CALCIUM SULPHATE SCALINGIRON FOULING

How to maintain PHEsBack flush the PHE once a week.check the PHE for leaks, especially during intense running periods.Check Regularly the gaskets as soon as possible for softness & elasticity, as brittle gaskets are no good.Install a water cleaning system. It will soften the water & will prevent hard scaling and fouling from coating the plates. Even chlorination should be proper.

Effective Heat Transfer- Large surface areas and corrugated plates allow Plate heat exchangers to transfer heat very efficiently. Easy MaintenanceCompact DesignCost-efficient- PHE are smaller and use less material to produce.Materials- PHE are available in a wide variety of materials. Plates are available in: Stainless Steel, Titanium, Titanium-Palladium, Nickel etc. as per our requirement.

Gasketed PHESemi-welded PHEWelded PHETypes of PHE

1.Gasketed PHE-use high quality gaskets and design to seal plates together and protect against leaks. Plates can easily be removed for cleaning. expansion, or replacing purposes,drastically reducing maintenance costs. Applications include- Chemical, HVAC etc.

2.Welded PHE- Here plates are welded together. Extremely durable, ideal for transferring fluids with high temperatures or corrosive materials.Mechanical cleaning of plates is not anoption as with PHE due to welding. Applications include- Hazardous liquids, oil cooling

3.Semi-welded PHE A mixture of welded and gasketed plates.Contains pairs of two plates welded together which are then gasketed to other pairsEasy to service on one side and able to transfer more intense fluids on the other. They are perfect for transferring expensive materials sincethey have a very low risk of fluid loss.

limitationsExtreme temperature difference b/w 2 fluids-its generally more cost efficient to use aShell & Tube heat exchanger.As in a Plate heat exchanger, there can be a high pressure loss due to the large amount of turbulence created by the narrow flow channels.

Gasketed Plate Heat Exchangersare limited in high fluid temperatures, by the temperature limitations of the gasket.

BRAZED HEAT EXCHANGER (BHE)

BHE is a compact variation of PHE but does not have carbon steel frame, gaskets or tightening bolts.It simply has AISI 316 stainless steel corrugated channel plates and the heat exchangers are brazed in a vacuum furnace and helium pressure tested to ensure leak-free performance.No pressure retaining parts such as shell of a shell and tube type etc.This combination with maximum heat transfer and high efficiency make it the most efficient HX.BHE

WORKING OF BHEEXPLODED VIEW OF BHE

Top view of BHE; GEA MAKE; AXLE PLANTGEA MAKE BHE;AXLE PLANT

OPERATING PRINCIPLEBased on the plate and nozzle orientation, each fluid passes through alternative channels within the heat exchanger. All plate material and nozzles are of Stainless Steel 316.An extremely high heat transfer coefficient is attained due to the flow characteristics in each channel. A specially designed and tested chevron pattern causes a turbulent flow of the fluid resulting in higher heat transfer.

TYPES OF BHETPL SERIES- In case of media with average viscosity and high viscosity.The TPL unit has special turbulators placed between the flow of gaps and by diagonal media flow together with large diameter connections very high heat exchangers rates are reached.GPL SERIES- Heat transfer plates with V-corrugation for universal application in case of media with low velocity. GPL series has thermally optimized plate corrugation which produces highly turbulent flow even in case of low mass flow.

TPL SERIES GPL SERIES

CB-COPPER BRAZED HXThese heat exchangers from the smallest unit CB14, to the largest unit CB300, are brazed with 99.9 % copper.This forms a self-contained unit that can handle both high pressures and high temperatures.The exceptional heat transfer efficiency makes all CB units very compact. As a result, they can tackle large-capacity duties even though there is only limited installation space available.

CB- COPPER BRAZED HX

Fusion bonded PHEAlfaNova, the worlds first 100% stainless steel AND fusion brazed plate heat exchanger,Extreme temperature and pressure fatigue conditions that would destroy a conventional brazed heat exchanger are no match for the rugged AlfaNova.compact, high-performance AlfaNova offers levels of hygiene and corrosion-resistance unmatched by any other BHE or any HX.

ALFANOVA- FUSION BONDED PHE

ADVANTAGES OF BHEHigh corrosion resistant- All plates uses SUS316 material. High pressure resistantHigh thermal efficiencyHigh working temperature- Brazed Plate Heat Exchanger's SUS316 material structure offers higher working temperature range up to 200.CompactnessLow maintenance- The corrugated plates are designed to achieve turbulence flow at a low flow rate, thus decreasing the need for frequent maintenance.

How to maintain BHEsFor heavier fouling use chemicals such as formic acid, citric acid in concentration compatible with copper.Use CIP(cleaning in place) systems to chemically remove calcium deposits and other forms of scaling from different plate surfaces.Do not leave the unit on standby after cleaning.Do not use liquids that are corrosive to stainless steel or brazing material(Cu or Ni).

SHELL & TUBE TYPE HXsWater to water heat exchanger

consists of a shell (a largepressure vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another fluid flows over the tubes (through the shell) to transfer heat between the two fluids.

Tube pitch- The shortest distance between centers of two adjacent tubes is called the tube pitch, should not be less than 1.25 times the tube diameter. Baffles- Responsible for obstructing and redirecting the flow of fluid in the shell side of an exchanger. Situated normal to the walls of the shell and force the liquid to flow at right angles to the axis of the tubes Thus increasing turbulence resulting in greater heat transfer.

Exploded view of shell and tube heat exchanger

Yantra make HX ; shell and tube type; TRACTOR PLANT( ENGINE SHOP)

Shell and tube type HX in diesel generators; utility area

How to Maintain shell & tube HXAt regular intervals , an examination should be made of internal as well as external of HX.Intervals b/w cleaning should not inc. because difficulty of cleaning will inc., as scaling or deposits on tubes will inc.Before disassembly, make sure that unit has been depressurized, vented and drained of all hazardous materials purged.Circulate hot wash oil and hot water with high vel. to remove sludge and salt deposits from tubes.

Forced draft ventilation

Controls indoor air quality.Excess humidity, odors & contaminants controlled via dilution or replacement with outside air.Ventilation includes both the exchange of air to the outside as well as circulation of air within the building.

PIE CHART SHOWING HX DISTRIBUTION

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TOTAL NO. OF HEAT EXCHANGERS IN CNH- 71

NO. OF RADIATOR TYPE HX - 46 TRACTOR PLANT -27 AXLE PLANT 16 UTILITY AREA- 3NO. OF PLATE TYPE HX- 8COOLANT TOWER- 6 NO. OF BRAZED TYPE HX- 5NO. OF SHELL &TUBE TYPE HX- 6 TRACTOR PLANT- 2 UTILITY AREA - 4

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsRHETRACTOR MACHINE#533 MAKINO A77DAIKINRHETRACTOR MACHINE#682 MAKINO A77DAIKIN 90507RHETRACTOR MACHINE#615 MAKINO A81DAIKINRHETRACTOR MACHINE#534 MAKINO A77DAIKINRHETRACTOR MACHINE#683 MAKINO A77DAIKIN40807RHETRACTOR MACHINE# 195 MAKINO A81DAIKINTRACTOR MACHINE#50437 HELLER MCH 300BKWRHETRACTOR MACHINE#725 MAKINO A81YUKENRHETRACTOR MACHINE#442 MAKINO A81YUKEN

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsRHETRACTOR MACHINE#441 MAKINO A81DAIKINRHETRACTOR MACHINE#352 MAKINO A77DAIKINRHETRACTOR MACHINE#685 MAKINO A77DAIKINRHETRACTOR MACHINE#485 MAKINO A77DAIKINRHETRACTOR MACHINE#351 MAKINO A81DAIKINRHETRACTOR MACHINE#456 MAKINO A77DAIKINRHETRACTOR MACHINE#533 MAKINO A77DAIKIN 80017RHETRACTOR MACHINE#684 MAKINO A77DAIKINRHETRACTOR MACHINE#682 MAKINO A77DAIKIN70704

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsRHETRACTOR MACHINE#440 MAKINO A77 DAIKINRHETRACTOR MACHINE#485 MAKINO A77DAIKINRHETRACTOR MACHINE#634 MAKINO A77DAIKINRHETRACTOR MACHINE#684 MAKINO A77DAIKIN RHETRACTOR MACHINE#456 MAKINO A77DAIKIN RHETRACTOR MACHINE#607 MAKINO A81DAIKIN RHETRACTOR MACHINE#352 MAKINO A81DAIKIN RHETRACTOR MACHINE#195 MAKINO A81 DAIKIN RHETRACTOR MACHINE#532 MAKINO A77DAIKIN

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsSHELL AND TUBE TYPETRACTORENGINE SHOPENGINE ASSEMBLY TEST CELL 4YANTRA

RHETRACTORMACHINE SHOP#50604 HELLER MCH 300BKWWRK10/2R28-CH2RHETRACTORMACHINE SHOP#50603 HELLER MCH 300BKWWRK10/2R28-CH2

RHETRACTORMACHINE SHOP#50437 HELLER MCH 300BKWWRK10/2R28-CH2

RHETRACTORMACHINE SHOP#50239 HELLER MCH 300BKWWRK10/2R28-CH2

RHETRACTORMACHINE SHOP#50240 HELLER MCH 300BKWWRK10/2R28-CH2

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsPHETRACTOR PAINT SHOPCHESSISE PHEAlfa lavalAM 10 FM1PHETRACTOR PAINT SHOPPRE DEGREASING TANK NO.1Alfa lavalP2FL1 (OLD)PHETRACTOR PAINT SHOPDEGREASING-1 TANK NO. 2Alfa lavalP2FL1PHETRACTOR PAINT SHOPDEGREASING-2 TANK NO. 3Alfa lavalP2FL1PHETRACTOR PAINT SHOPPHOSPHATE TANK NO. 7Alfa lavalP2FL1 (OLD)PHETRACTOR PAINT SHOPPHOSPHATE TANK NO. 7Alfa lavalM6-MFG (NEW)PHETRACTOR PAINT SHOPCED BATH TANK NO. 11Alfa lavalP2FL1 PHETRACTOR PAINT SHOPPRE DEGREASING TANK NO.1Alfa lavalM6-mfg (NEW)

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsBRAZED HXsTRACTORNDL (NEW DRIVE LINE)NDL M/C 1FUNKEBRAZED HXsTRACTORNDL (NEW DRIVE LINE)NDL M/C 2FUNKE

RHEAXLEDIFFERENTIAL LINE BEMCOWARKINRHEAXLEDIFFERENTIAL LINEHIND HH473-11797GK ENGG.HH5C-PLCRHEAXLESTEERING KNUCKLE LINEBEMCO 20TonWARKINDSL 50RHE AXLESTEERING KNUCKLE LINEHIND 5TonGK ENGG. HH5C-PLCRHE AXLE STEERING KNUCKLE LINEBEMCO 20TonWARKINDSL 50RHE AXLE STEERING KNUCKLE LINEBEMCO 20TonWARKINDSL 50RHE AXLESTEERING KNUCKLE LINEHIND 5TonGK ENGG.HH5C-PLC

TYPE OF HXsPLANTLINE/SHOPM/C NAMEMAKE OF HXsMODEL/TYPE OF HXsRHEAXLEPLANET CARRIER LINEBEMCO 40TonWARKINDKL 307RHEAXLE PLANET CARRIER LINEBEMCO 40TonWARKINDKL 307RHEAXLEMACHINE SHOPMAC 6290 MAKINO A100E YUKENRHEAXLEMACHINE SHOPMAC 11173 MAKINO A100EYUKENRHEAXLEMACHINE SHOPMAC 6291 MAKINO A100E YUKENRHEAXLEMACHINE SHOPMAKINO A81YUKENRHEAXLEMACHINE SHOPMAKINO A81YUKEN

TYPE OF HXPLANTSHOPMACHINE NAMEMAKEMODELRHETRACTORDRIVE LINE#50525 HELLER MCH 300BKWWRK10/2R28-CH2 RHETRACTORDRIVE LINE#50237 HELLER MCH 300BKWWRK10/2R28-CH2 RHETRACTORDRIVE LINE#51276 HELLER MCH 300BKWWRK10/2R28-CH2 BHEAXLEM/C SHOPFAMAR ERGO 500GEAWP 1-24EBHEAXLEM/C SHOPFAMAR ERGO 500GEAWP1-24EBHEAXLEM/C SHOPFAMAR ERGO 500GEAWP 1-24E

Contingency plans

Radiator type HX

BRAHMASTRA FOR PHEWhen the level of problem is at a level where above written precautions dont work then use BRAHMASTRA that is contact the vendor. And here its ALFA LAVAL.

NAME: ALFA LAVAL INDIA LTD.ADDRESS: 704-705,Ansal bhavan,16, Kasturbha Gandhi Marg , DelhiPHONE NO: 01141293300EMAIL ID: india.info@alfalaval.com

Brahamastra for BHEwell it does not have any modes of failure except that it stops working, so in that case is contact the vendor. And here its FUNKE and GEA.

NAME: Funke heat exchangers India pvt ltd. ADDRESS:14, Hadapsar Industrial estate, Hadapsar, Opposite Kwality bakery,Pune. CONTACT PERSON: Ashish B Kale PHONE NO:02066047894,9403961354 EMAIL ID: info@funke.co.in

NAME: GEA Ecoflex India Pvt Ltd.ADDRESS: R-493, MIDC, TTC Industrial Area, Rabale 400701 Navi Mumbai IndiaCONTACT PERSON: Virendra JhambFAX: +91 22 27693797EMAIL ID: virendra.jhamb@geagroup.com

Universal

PHE

SHELL & TUBE

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