Plant Equipment

Heat ExchangersI n t e g r a t i o n a n d P r o f e s s i o n a l i s m

DR. ENG. MOHAMED AL-KHAWAGA

Update: November 2016

I N A C C O R D A N C E W I T H

TEMA STANDARD

HEAT EXCHANGER HANDBOOK

P L U S I N T E R N A T I O N A L C O D E S W H I C H P R O V I D I N G

P r a c t i c a l s o l u t i o n & A c a d e m i c S t u d i e s

P E T R O P R O J E C TI N T E R N A T I O N A L C O R P O R A T I O N

R E A L I S T I C I N N O VA T I O N

P R A C T I C A L S O L U T I O N

P R E FA C E

PROGRAM STRUCTURE AND GUIDANCEBODY OF KNOWLEDGE AND OVERVIEW

Eng. Mohamed Alkhawaga Nov. 016 2

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

B o d y K n o w l e d g e

Module I.

PREFACE AND OVERVIEW

Heat Transfer Philosophy and methodology and other concepts

Module II.

H. EX. TYPES AND CLASSIFICATION

Illustration of H. Ex. Classification in depending on industries types and related to process targets

P L A N T E Q U I P M E N T

HEAT EXCGANGERS

I . PREFACE

Module III.

H. EX. DESIGN

Specific overview for all design recommendation

Module IV.

H. EX. Construction

Specific overview for all fabrication, Quality and installation gaudiness

Module V.

H. EX. MAINTENANCE

Specific overview for Inspection, repair and cleaning

O v e r v i e w

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . PREFACE

H E AT T R A N S F E R

Heat always moves from a warmer place to a cooler place.Hot objects in a cooler room will cool to room temperature.Cold objects in a warmer room will heat up to room temperature.

HE

AT

TR

AN

SF

ER

ME

TH

OD

S

Conduction

Convection

Radiation

H . E X . P a r t s

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . PREFACE

MA

IN

C

OM

PO

NE

NT

S / P

AR

TS

Vessel [Body]

Floating Head

Channel

Channel Cap

Tube Bundle

Baffles

Guides

Nozzles

Supports

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . PREFACE

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . PREFACE

H . E X . P & I D

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . PREFACE

H . E X . P r o c e s s i n g

C O L D F L U I D T H E N H O T F L U I D

M E T A L

Quenching

M o d u l e I I

HEAT EXCHANGER CLASSIFICATIONRELATED TO INDUSTRIES

Eng. Mohamed Alkhawaga Nov. 016 9

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . H. Ex. Classification

Classification According to Transfer Process

Direct Contact TypeIn-Direct Contact Type

Direct Transfer Type Strong Type Fluidized bed

Immiscible fluid Gas - Liquid Liquid - VaporSingle Phase Multi Phase

Classification According to Number Of Fluid

N Fluids [N>3]Two Fluids Three Fluids

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . H. Ex. Classification

Classification According to Surface Compactness

Liquid to LiquidGas To Fluid

Compact Non-Compact

Classification According to Heat Transfer Mechanism

Combined Convection

and radiation heat

transfer

Single Phase

Convection in both side

Single Phase

Convection in one side

Two Phase Convection

in other side

Compact Non-Compact

𝛽 ≥ 700𝑚2

𝑚3 𝛽 < 700𝑚2

𝑚3 𝛽 ≥ 400𝑚2

𝑚3𝛽 < 400

𝑚2

𝑚3

Two Phase Convection

in both side

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . H. Ex. Classification

Classification According to Construction

RegenerativeTabular

Printed

Plate Type Extended Surface

PHA Spiral Plate Coil

Casketed Welded Brazed

Tube FinPlate Fin

Ordinary Sep. Wall

Heat Pipe Wall

Rotary

Fixed Matrix

Rotating Hoods

Pipe coilDouble Pipe Shell & Tube Spiral Tube

Parallel Flow to tube Cross flow to tube

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . H. Ex. Classification

Classification According to Flow Arrangement

Multi PassSingle Pass

Counter Flow Parallel Flow

Extended Surface Plate

Cross Flow Split Flow Divided Flow

Fluid 1 m passes

Fluid 2 n passesCr. ounter Flow Cr. Parallel Flow Compound Flow

Shell and Tube

P. Counter Flow Split Flow Divided Flow

M shell passes

N Tube passes

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . H. Ex. Classification

Concentric-Tube Heat Exchangers

Simplest configuration.

Superior performance associated with counter flow.

Parallel Flow Counterflow

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

I . H. Ex. Classification

Cross-flow Heat Exchangers

For cross-flow over the tubes, fluid motion, and hence mixing, in the transverse direction (y) is prevented for the finned tubes, but occurs

for the unfanned condition.

Heat exchanger performance is influenced by mixing.

Finned-Both Fluids

Unmixed

Unfinned-One Fluid Mixed

the Other Unmixed

PLANT EQUIPMENT

HEAT EXCHANGERS

II. H. EX. CLASSIFICATION

Shell-and-Tube Heat Exchangers

Baffles are used to establish a cross-flow and to induce turbulent mixing of the shell-side fluid, both of which enhance convection.

The number of tube and shell passes may be varied, e.g.:

One Shell Pass, Two Tube Passes Two Shell Passes, Four Tube Passes

PLANT EQUIPMENT

HEAT EXCHANGERS

II. H. EX. CLASSIFICATION

Compact Heat Exchangers

Widely used to achieve large heat rates per unit volume, particularly when one or both fluids is a gas.

Characterized by large heat transfer surface areas per unit volume, small flow passages, and laminar flow.

(a) Fin-tube (flat tubes, continuous plate fins)

(b) Fin-tube (circular tubes, continuous plate fins)

(c) Fin-tube (circular tubes, circular fins)

(d) Plate-fin (single pass)

(e) Plate-fin (multipass)

M o d u l e I V

HEAT EXCHANGER MAINTENANCERECOMMENDATION PRACTICE

Eng. Mohamed Alkhawaga Nov. 016 18

P L A N T E Q U I P M E N T

HEAT EXCHANGERS

19

GENERAL ASSEMBLY VIEW

Shell side Inlet

Shell side Outlet

Tube side Inlet

Tube side Outlet

Shell

Back Cover

Distributor

Tube Sheet

Gaskets

Gasket

Saddle

Floating HeadBundle

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

20

CROSS SECTIONAL VIEW

BaffleShell

Distribut

or

Back cover

Tube Bundle

Floating

Head

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

21

Split ring

Distributor Back CoverFloating

Head

GasketSpacerGasket GasketGasket

Shell

Floating

Head Detail

Tube Bundle

Tube sheet Tube sheet

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

22

Do Not Start The Job Without A Safety Plan

23

Bundle Puller

MAINTENANCE ACTIVITY DESCRIPTION

Blind Inlets-Outlets at plant

area

Disconnect and remove

Distributor with gasket

Disconnect and remove Back

cover with gasket

Disconnect and remove

Floating Head with gasket

Install the bundle puller

Pull the bundle out

Ground level

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

24

Bundle Puller

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION

Clean Shell and covers Lift the bundle puller with clean

bundle and new gasket, ready

for reinstallation

Lower the bundle and take to

hydro-jetting area

Ground level

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

25

Bundle Puller

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION

Reinsert the bundle by bundle

puller

Lower the bundle puller to the

ground and take it away

Ground level

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

26

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION

Install front Test Ring with gasket

Install back Test Ring with

gasket

Fill the shell by water

Install Pressure Gauge

Ground level

SHELL SIDE HYDRO-TEST

PG

Install Blinds in shell

Water Pump

Connect water pump Check leakages from tubes

Raise the pressure up to value

given by Inspection

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

Water

Water

SHELL SIDE HYDRO-TEST

CHECK LEAKAGES FROM TUBES CONTINUATIONPG

“A” “B”

View “B”View “A”

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION

28

TUBE LEAK ELIMINATION DETAILS

Detail “B” [By Plug both

sides]

Detail “A” [By Expansion both sides]

Leak

Leak

SHELL SIDE HYDRO-TEST

Tube Expander

Tool

PG

“A” “B”Shell under pressure

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

29

PG

Remove Test Ring & gasket

[distributor side]

Reinstall distributor with new

gasket & tight bolts

Remove Test Ring & gasket

[floating head side]

Reinstall Floating Head with split

flange, new gasket & tight bolts Blind Distributor in & out

Discharge water from shell

drain

Drain

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION TUBE SIDE HYDRO-TEST

PG

Check distributor gasket sealing

Check floating head gasket

sealing

PG

Fill tube side by water

Drai

n

Install PG in distributor top

nozzle

Connect water pump

Water Pump

Raise the pressure up to value

given by Inspection

Discharge the water, remove PG and water

pump

Remove blinds form distributor

nozzle and tight bolts

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION TUBE SIDE HYDRO-TEST

31

PG

Check bundle to shell gasket sealing

Check Back cover gasket

sealing

Fill Shell side by water

Drai

n

Install Back cover with Gasket

Water Pump

Raise the pressure up to value

given by Inspection

Discharge the water, remove PG and

water pump

Remove blinds form shell nozzles

and tight bolts

Connect water pump

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION SHELL FINAL SIDE HYDROTEST

Close Work permit Remove tools and equipment

Clean and wash the area Remove scaffold after unit start-up

PLANT EQUIPMENT

HEAT EXCHANGERS

V. H. EX. MAINTENANCE

SHELL & TUBE HEAT EXCHANGERS

MAINTENANCE ACTIVITY DESCRIPTION…..CONTINUATION HANDING OVER