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CONTENTS Page 0.0 Cover Sheet List of drawings 1.0 2.0 3.0 4.0 5.0 6.0 Introduction Location Access for Operation & Maintenance Key Words Steps to do Heat Exchanger Piping Heat Exchanger Piping 1 2-3 4 4-5 5 6 6-7 7-8
Checked:
Approved:
SR.NO. DWG.NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 HEP1 HEP2 HEP3 HEP4 HEP5 HEP6 HEP7 HEP8 HEP9 HEP10 HEP11 HEP12 HEP13 HEP14 HEP15 HEP16 HEP17 HEP18 HEP19 HEP20 HEP21 HEP22 HEP23 HEP24 HEP25
DESCRIPTION
EXCHANGER APPLICATION SHOWN ON A PROCESS FLOW DIAGRAM SHELL AND TUBE HEAT EXCHANGER WITH REMOVABLE TUBE BUNDLE SAMPLE OF TUBE AND SHELL EXCHANGER PASSES TYPES OF EXCHANGER : SHELL & TUBE, PLATE TYPE & AIR COOLER EXCHANGER AIR COOLER EXCHANGER CONSTRUCTION DETAILS TYPICAL PLOT PLAN OF SEVERAL EXCHANGER APPLICATION ARRANGEMENT OF EXCHANGERS AND OPERATING SPACE BETWEEN PIPING SAMPLE EXCHANGER ORIENTATION SAMPLE SINGLE & PAIRED EXCHANGER/PARALLEL & SERIES INSTALLATIONS STACKED EXCHANGER INSTALLATION SAMPLE STRUCTURE MOUNTED EXCHANGER INSTALLATION TOWER SUPPORTED VERTICAL INSTALLATION & TUBE BUNDLE MAINTENANCE STRUCTURE SUPPORTED VERTICAL INSTALLATION CONTROL AND OPERATOR ACCESS FOR A PLATE TYPE HEAT EXCHANGER TYPICAL COLUMN SUPPORTED AIR COOLER ARRANGEMENT TYPICAL FIXED PLATFORM AIR COOLER ARRANGEMENT ALLOWABLE NOZZLE CONFIGURATIONS EFFECT OF ELBOW NOZZLES ON STACKED EXCHANGERS ALTERNATE AIR COOLER NOZZLE CONFIGURATIONS PIPING TO NOZZLES OF HEAT EXCHANGERS ALTERNATE ARRANGEMENTS FOR LOCATING EXCHANGER NOZZLES PIPING ARRANGEMENT FOR HORIZONTAL SHELL AND TUBE EXCHANGERS SUPPORTS FOR PIPING ARRANGEMENT PIPING ARRANGEMENT FOR UNDERGROUND COOLING WATER SYSTEM PIPING ARRANGEMENT FOR STEAM AND CONDENSATE SYSTEM
SR.NO. DWG.NO.
27 28 29 30 31 HEP27 HEP28 HEP29 HEP30 HEP31
DESCRIPTION
PIPING ARRANGEMENT FOR HIGH TEMPERATURE & PRESSURE FEED EXCHANGERS PIPING ARRANGEMENT FOR FEED EXCHANGERS PIPING ARRANGEMENT FOR SPIRAL EXCHANGERS PIPING ARRANGEMENT FOR PLATE EXCHANGERS OVERHEAD PIPING ARRANGEMENT FOR A CONDENSING AIR COOLER
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). Various process duties of heat exchanger have an effect on the layout aspects viz. a. Exchange of sensible heat between two process fluids. b. Cooling with air or water. c. Chilling with refrigerated liquid. d. Heating with steam or hot water. e. Condense by water or a cold process stream. f. Vapourising by steam (e.g. column reboiler) or any heat transfer liquid. 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.
1.1
1.2
1.3
Various types of heat exchangers with application are illustrated in the schematic flow diagram HEP1. The various parameters applied to heat exchangers are illustrated in Fig., HEP2, HEP3, HEP4 & HEP5. 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. 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
1.4
2.0
maintenance. 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 oblong 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 for reversing flows. Exchangers are sometimes mounted on structures, process columns and other equipment. Special arrangements for maintenance and tube cleaning should be provided in such cases.
3.0
ACCESS FOR OPERATION & MAINTENANCE Internals of heat exchanger require periodic cleaning and repair. It is important that exchangers and the surrounding piping are arranged to facilitate access to the internal parts.
3.1
Horizontal clearance of at least 900mm should be left between exchangers flange to flange or exchanger flanges to piping. Where space is limited, clearance may be reduced between alternate exchangers but in no case clearance over insulation between channel flanges shall be less than 600mm. The channel ends of exchangers should face the local access road for tube 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 500mm more than the bundle length.
3.2
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 minimum. 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 out of its shell with pull rod attachments that use hydraulic force. 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. Provision of easily removable spool pieces, flanged elbows, break flanges or short pipe runs will be helpful for maintenance of exchangers. 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.
3.4
3.5
3.6
3.7
4.0
KEY WORDS Shell and Tube Fixed head Floating head Channel End Bonnet End Channel Flange Tube bundle removal Air Cooler (Fin-Fan) Header Box Nozzle loads Platform Support Structure Stacked heat exchanger Elbow nozzle. Monorail Maintenance accessway
Plate type heat exchanger Inlet port Back flashing Plates and gaskets Removal of individual plate
"STEPS TO DO HEAT EXCHANGER PIPING" Collect the mech. spec. of the heat exchanger. Study the P&ID around the heat exchanger and identify the relationship with the connected equipment viz. column or reactor. Note the special process (functional) requirement along with the specific arrangement details with respect to level or height difference from other related equipment like pumps. Study the nozzle schedule, its position on the equipment and verify with P&ID. 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. Locate the control valve stations both for shell side and tube side fluids. Decide the flanged joints location for replacement of Heat Exchanger / maintenance facility. 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.
Step 3 :
Step 4 : Step 5 :
Check, piping should not foul with exchanger removal either in the horizontal direction for bundle-pulling nor in the vertical for whole exchanger removal. 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. Mark the supports / support arrangement on the piping study. Ensure accessibility / operation facility for all valves as well as the clearance kept are not less than the recommended minimum requirement.
Step 10:
6.0 6.1
HEAT EXCHANGER PIPING SHELL & TUBE 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 control stations. 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, if 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.
6.2
PLATE & SPIRAL 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 HEP30 illustrates the typical piping arrangements around spiral & plate exchangers.
6.3
AIR COOLERS Piping for air coolers a not routed over tube banks or fans and should be kept clear of the re designated space for motor maintenance. Fig.HEP31 illustrates the typical piping arrangements around air coolers.
Page
AIR
HEATER
CHILLER
KETTLE
REFRIGERANT
REFRIGERATION PACKAGE
Page
CHANNEL COVER CHANNEL HEAD NOZZLE 1ST FLUID ENTERS (COLD) 2ND FLUID LEAVES (WARM) SHELL NOZZLE RELIEF VALVE CONNECTION REMOVABLE TUBE BUNDLE SHELL NOZZLE
PACKED FLOATING TUBE-SHEET FLOATING HEAD RING 2ND FLUID ENTERS (HOT)
SHELL VENT
DRAIN DRAIN 1ST FLUID LEAVES HEAD NOZZLE SADDLE BAFFLE(TYP) SADDLE
Page
VERTICAL BAFFLES
IN
CHANNEL HEAD HORIZONTAL BAFFLE TUBE NOZZLE TUBE BUNDLE VERTICAL BAFFLES SHELL COVER
SHELL SIDE
SHELL
SHELL NOZZLE
Page
PLATE EXCHANGER
Page
HEADER BOX
FAN HOUSING
TUBE BANK
INLET NOZZLE
MOTOR
SUPPORT STEEL
OUTLET NOZZLE
HEADER BOX
INLET NOZZLE
SUPPORT CHANNEL
Page
C COLUMN L
SPIRAL EXCHANGERS
PRODUCT COOLERS
Page
(a)
2" MIN. CLEARANCE 2'-6" (750) 2" MIN. SPACE FOR PULLING TUBES 2'-6" (750) ACCESS
PIPERACK
6' (1800)
L FEET
(0.8)(L)FEET
8FEET (2500)
(b)
ARRANGEMENT OF EXCHANGERS WITH 2'-0" MAINTENANCE SPACE BETWEEN PAIRED UNITS AND 2'-6"OPERATING SPACE BETWEEN PIPING.
2' (600)
ACCESS
2'
6' (1800)
L FEET
(0.8)(L)FEET
8FEET (2500)
(1) SHOW OUTLINES OF EXCHANGER SUPPORTS OR FOUNDATIONS BEFORE ARRANGING PIPING. (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.
Page
C TOWER L
- CHANNEL END TO FACE MAINTENANCE ACCESS WAY FOR TUBE BUNDLE REMOVAL. - PROVISION OF ADEQUATE SPACE FOR BONNET REMOVAL.
DAVIT
CHANNEL END
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OPERATOR ACCESS
OPERATOR ACCESS
OPERATOR ACCESS
SINGLE EXCHANGER
PAIRED EXCHANGERS
OPERATOR ACCESS
OPERATOR ACCESS
OPERATOR ACCESS
OPERATOR ACCESS
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ELBOW NOZZLE 12'-0"/3600 (MAXIMUM WITHOUT PLATFORM) SAME SERVICE SPACE FRAME OPERATOR ACCESS AREA
SAME SERVICE
DISSIMILAR SERVICE
Page
4'-0"/1.200 MIN.(TYP.)
TUBE END
18"/.450 MIN.
Page
TUBE BUNDLE REMOVAL AREA TOWER ALTERNATIVE CHANNEL DESIGN LUG & SPRING 2'/600 TO 5'/1500
PLATFORM REBOILER HITCH POINTS FOR COVER REMOVAL 12'-0"/ 3600 MAXIMUM WITHOUT PLATFORM 3'-0"/ 900 MIN. VESSEL NOZZLE LUG & SPRING 1"/.025 GAP
GUIDE
UN-BOLT
EXTRACT TUBE-BUNDLE
Page
LUGS
6'-0"/1800 (MAXIMUM) PLATFORM 18"/450 MINIMUM 12'-0"/3600 MAXIMUM WITHOUT PLATFORM 3'-0"/900 MINIMUM
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OPERATOR ACCESS
OPERATOR ACCESS
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MOTOR
7'-0"/2100 MIN.
MOTOR
(TYP.)
MAINTENANCE PLATFORM
OPERATOR ACCESS
(TYP.)
LADDER
PIPE RACK
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MOTOR (TYP.)
MAINTENANCE PLATFORM
Page
Page
ELBOW NOZZLES
REDUCTION IN SPACE
ALTERNATIVE `A'
REDUCED SPACE
ALTERNATIVE `B'
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AIR COOLERS
C TOWER L
ALTERNATE LOCATION
Page
TO ALLOW LIFTING OF REAR HEAD FOR MAINTENANCE, PIPE MAY BE OFF SET AS SHOWN, OR A SHORT SPOOL CAN BE PROVIDED. REMOVABLE SPOOL
LINES SUPPORTED UNDER AN EXCHANGER ARE SOMETIMES INSUFFICIENTLY FLEXIBLE. THE FLANGED JOINT AT THE HEAD NOZZLE TO BE PARTED AFTER REMOVAL OF BOLTS. IF THIS IS LIKELY A SHORT REMOVABLE SPOOL TO THE HEAD NOZZLE SHOULD BE PROVIDED.
C EXCHANGER L
ALLOW SPACE FOR PULLING TUBES OBLIQUE OFFSETS IN PIPING SIMILIAR TO THOSE SHOWN. ALLOW EXCHANGERS TO BE PLACED CLOSER. CONSIDER REQUEST TO VENDOR DIFFERENT NOZZLE TYPES, ORIENTATIONS AND LOCATION TO OBTAIN THE BEST PLANT ARRANGEMENT. 90ELBOW NOZZLE 90ELBOW NOZZLE
Page
ALTERNATIVE `A'
ALTERNATIVE `B'
Page
450
450
600 TO 900
MAINTENANCE ACCESS
CONTROL STATIONS
TUBE BUNDLE REMOVAL AREA= TUBE LENGTH + 450 CHECK CLEARANCE AT SUPPORT ACCESS TO VALVES & INSTRUMENTS
C TOWER L
PIPE RACK
BREAK FLANGES
MAINTENANCE ACCESS
CONTROL STATIONS
Page
INTERMEDIATE SUPPORT REQUIRED FOR PIPING THAT IS OVER SPANNED BETWEEN PIPE RACK AND EXCHANGERS
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THI
COOLING WATER SUPPLY COOLING WATER RETURN CHECK CLEARANCE WITH FOUNDATIONS
ANTIFREEZE BYPASS
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CONDENSATE POT
LEVEL GAUGE
TRUNNION SUPPORT
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SYMMETRICAL PIPING
LUGS
Page
ALTERNATIVE `A'
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COOLING WATER
Page
OPERATOR ACCESS
CONTROL VALVE
CONTROL VALVE
Page
OPERATOR ACCESS
CONTROL VALVES
PLAN
ELEVATION
Page
AIR COOLER
COST EFFECTIVE ALTERNATE ROUTING, IF PIPING IS FLEXIBLE AND CAN SPAN DISTANCE WITHOUT INTERMEDIATE SUPPORT.
AIR COOLER
C TOWER L FOR FLEXIBILITY, THE AIR COOLER CAN BE POSITIONED WITH THE INLET NOZZLES ON THE FAR CENTERLINES OF THE PIPE RACK COLUMNS. THE AIR COOLER SECTIONS SHOULD BE SEGREGATED AND THE STEEL EXTENDED TO SUPPORT THE OVERHEAD PIPING.