Heat Transfer Equipment

Presentation by
LARSEN & TOUBRO LIMITED
M. VENKATESH
Tel: (022) 67053406
e-mail: venkatesh.m@hed.ltindia.com

18 Sep.2008
 Types of Heat Exchangers
Tubular heat exchangers

Shell & Tube Heat Exchangers

Double Pipe Heat Exchangers

Multi-Tube Heat Exchangers

Air-Cooled Heat Exchangers

Non-tubular Heat Exchangers

Plate & Frame Heat Exchangers

Spiral Plate Heat Exchangers

18 Sep.2008
 Shell & Tube Heat Exchangers
Used in all process industries
Chemical plants
Oil & Gas industry
Petroleum refineries
Petrochemical plants
Fertilizer industries
Power plants
Workhorse of the industry.
No limitations on size, design pressures, design temperatures
and materials of construction.
An extremely wide range of flow rates and heat loads can be
accommodated by varying diameters, tube lengths, tube pitch,
number of shell side passes, shell baffle spacing etc.
18 Sep.2008
 Shell & Tube Heat Exchangers
Shortcomings
Inefficient conversion of pressure drop to heat transfer due to
Continuously varying flow area & velocity
Zig-zag flow pattern with multiple bends
Back-mixing in dead zones behind baffles

18 Sep.2008
 Double Pipe Heat Exchangers

18 Sep.2008
 Double Pipe Heat Exchangers
Two concentric pipes .
One fluid flows in inner pipe while
the other fluid flows in annular
gap.
Can have multiple sets connected
in series or in parallel or in series-
parallel combination.
Used for low flow rate and heat
duty applications.
Small surface area achievable.
Inner pipe can be plain or
longitudinally finned.
18 Sep.2008
 Multi-Tube Heat Exchangers

18 Sep.2008
 Multi-Tube Heat Exchangers

18 Sep.2008
 Multi-Tube Heat Exchangers
U-tube type heat exchanger having one leg in one shell and

other leg in second shell.

Equivalent to shells in series.

U-bend surface area is effective for heat transfer.

True counter-current flow; can avoid temperature cross.

Can be used with plain tubes, longitudinal fin tubes and

twisted tubes.

Can be used for high pressure applications.

18 Sep.2008
 Air-Cooled Heat Exchangers

18 Sep.2008
 Air-Cooled Heat Exchangers

18 Sep.2008
 Air-Cooled Heat Exchangers

18 Sep.2008
 Air-Cooled Heat Exchangers

18 Sep.2008
 Air-Cooled Heat Exchangers
Used when reliable source of cooling water is not available.

Requires large plot size.

Finned tubes used due to low heat transfer coefficient of air.

Temperature of process fluid is governed by ambient air

temperature.

Requires controls such as variable pitch fan blades, variable

speed fans, louvers.

Steam coils / air recirculation system provided for low

ambient temperature operations.

18 Sep.2008
 Air-Cooled Heat Exchangers

18 Sep.2008
 Air-Cooled Heat Exchangers

18 Sep.2008
 Plate & Frame Heat Exchangers

18 Sep.2008
 Plate & Frame Heat Exchangers

18 Sep.2008
 Plate & Frame Heat Exchangers
Consists of a pack of gasketed plates
held together between a frame plate &
a pressure plate.
Plates have chevron patterns.
Assembly held together by tightening
bolts.
Chevron patterns create metal-to-
metal contact between adjacent plates.
Each plate has holes called ports at the
four corners.
Ports form headers to distribute
respective fluids to opposite sides of
each plate.
18 Sep.2008
 Plate & Frame Heat Exchangers
Gaps between plates form
flow passages for the fluids.
Fluids are confined to heat
transfer surfaces of plates or
ports as appropriate by
gaskets (usually elastomers).
Hot & cold fluids flow in
alternate passages.
One fluid travels up one side
of a plate.
The other fluid flows down
the opposite side of the plate.
18 Sep.2008
 Plate & Frame Heat Exchangers
Compact design – higher surface area to volume ratio than
shell & tube heat exchangers.
Much higher heat transfer coefficient is achieved compared
to S&T heat exchangers; surface area can be one-third.
Easy to install and maintain.
Opening & closing a standard unit does not require
dismantling of piping.
Capacity can be expanded by simply adding more plates.
True counter-current flow; very low approach can be
achieved (as low as 1 C).
Pressure range is limited to 25 bar, temperature range is
limited by gasket materials.
18 Sep.2008
 Plate & Frame Heat Exchangers
Applications
Food industry
Pasteurizer
Water-water exchangers (auxiliary cooling water system)
Lean-Rich Amine exchangers
Liquid-liquid exchangers
Special designs of PHEs used for fluids containing fibres,
solids, crystals, pulp, viscous liquids
Sulphuric acid coolers

18 Sep.2008
 Spiral Plate Heat Exchangers

18 Sep.2008
 Spiral Plate Heat Exchangers

18 Sep.2008
 Spiral Plate Heat Exchangers
Two flat plates wrapped around a central core.

Two concentric channels of rectangular cross-section.

Spacing between plates maintained by studs welded to

plates.

End covers provided on either side of windings.

Hot and cold fluid media flow in alternate channels.

Complete access to both channels for mechanical cleaning.

18 Sep.2008
 Spiral Plate Heat Exchangers
Due to curved channel, turbulent flow achieved at much
lower Reynolds number than in tubes.

Compact size - smaller footprint.

Single channel - no flow maldistribution, no dead spots.

Self cleaning due to high shear rate.

True counter-current flow; close temperature approach is

possible.

Can handle fluids with high solids loading.

18 Sep.2008
 Spiral Plate Heat Exchangers
Applications
Fatty Acid Coolers
PVC Slurry Heat Exchangers
Column Interchangers
Lean / Rich Amine Exchangers
Bottoms Coolers
Vent Condensers
Column Overhead Condensers
Reboilers

18 Sep.2008
 Shell & Tube Heat Exchangers

18 Sep.2008
 Allocation of fluids

Nature of fluid (hazardous, corrosive, fouling etc)

State of the fluid (phase, pressure etc.)

Safety

Reliability

Operating company practice

Ease of maintenance

Capital cost

18 Sep.2008
 TEMA Standards

18 Sep.2008
 TEMA BEM Type

18 Sep.2008
 TEMA AEM Type

18 Sep.2008
 TEMA AES Type

18 Sep.2008
 Front Head Types
A Type (Channel and removable cover)
Flanged joints at both ends of channel.

Bolted to tubesheet at one end & flat cover

plate at the other end.

Cleaning of insides of tubes is possible without

removing the whole channel or associated
piping.

Relatively high cost due to two flanged joints.

Very widely used used, especially in petroleum

refineries.
18 Sep.2008
 Front Head Types
B Type (Bonnet)
Flanged joint at one end of channel.
Welded head at other end of channel.
Cheaper & lighter than A type.
Not recommended for exchangers requiring
frequent tube side cleaning.
For mechanical cleaning of tubes, bonnet &
associated piping must be removed.
Used for cleaner tube side fluids.
For large diameter bonnets, manway may be
provided to provide access without removing
bonnet and associated piping.
18 Sep.2008
 Front Head Types
C Type (Channel integral with tube
sheet)
Similar to A type, except that the channel
is welded directly to tubesheet.
Tubesheet extended & bolted to shell.
Shell is removable, channel & tube bundle
left in place.
Suitable for hazardous tube side fluids &
heavy, high pressure tube bundles.
Suitable for exchangers requiring more
frequent cleaning on shell side.
18 Sep.2008
 Front Head Types
N Type (Channel integral with tube
sheet)
Similar to C type, except tubesheet is welded
to shell.
Only applicable for fixed tube sheet
exchangers.
Tubes can be internally cleaned without
removing the channel or the associated piping.
Can be used for hazardous services.
Shell side cleaning is not possible.
Requires larger shell diameter.
18 Sep.2008
 Front Head Types
D Type (Special high pressure
closure)
Specially designed closure for high
pressures on tube side.
Tube sheet and channel are integral (drum
tube sheet).
Very large bolt sizes for channel cover
requiring use of hydraulic bolt tensioners.
Several designs available (some patented)
to reduce cost. Breechlock type is one
such proprietary design.
18 Sep.2008
 Rear Head Types
Can be broadly classified as

Fixed tubesheet type.

Floating head type.

U-tube type.

18 Sep.2008
 Rear Head Types
Fixed tube sheet
No access to outside of tube bundle.
Used with clean, non-corrosive shell side fluids which do
not require mechanical cleaning of shell side of tube
bundle.
Relatively cheap.
Large differential thermal expansion between shell & tubes
can lead to overstressing of tubes or damage to tube-to-
tubesheet joints.
Requires expansion joints or expansion bellows on shell to
overcome problem of differential expansion.
18 Sep.2008
 Rear Head Types
Floating Head
Tube bundle is removable.

Relatively more expensive.

Used when mechanical cleaning of shell side of tube

bundle is required.

Requires larger clearance between OTL and shell ID.

resulting large fluid bypass and leading to larger shell ID.

18 Sep.2008
 Rear Head Types
U-tubes
Commonly used for high pressure applications.

Relatively cheapest (eliminates one tubesheet, channel).

Removable tube bundle. Can be mechanically cleaned on

shell side.

Cannot be mechanically cleaned in U-bend region. Hence,

used with clean fluids on tube side.

Can handle large thermal differential expansion between

shell and tubes.

18 Sep.2008
 Rear Head Types
L Type
Fixed tube sheet arrangement.
Corresponds to A type front head.
Generally used with single or odd no. of tube
pass exchangers
Cleaning of insides of tubes is possible without
removing the channel.
M Type
Fixed tube sheet arrangement.
Corresponds to B type front head.
Generally used with even no. of tube pass
exchangers
18 Sep.2008
 Rear Head Types
N Type
Fixed tube sheet arrangement.
Corresponds to N type front head.
Generally used with single or odd no. of
tube pass exchangers
Cleaning of insides of tubes is possible
without removing the channel.
P Type:
In this the gap between the shell and the
floating tube sheet is sealed by
compressing packing material.
This is not suitable for hazardous and high
pressure applications.
18 Sep.2008
 Rear Head Types
S Type ( Floating head with backing
device)
Also called as split ring floating head
(SRFH).

Floating head is bolted to backing device.

Backing ring is split (made in two halves).

Commonly used with A type front end head.

AES is most common type in refinery

services.

18 Sep.2008
 Rear Head Types
T Type (Pull through floating head):
Rear end can be pulled through without
removing the floating head.
Requires larger shell diameter than S type.
Relatively costlier than S type.
Easier to dismantle than S type.
Commonly used in Kettle type heat
exchangers.
Preferred when there is large pressure
differential between shell & tube sides.
18 Sep.2008
 Rear Head Types
U-Type (U tube bundle)
Bundle is easily removable for external
cleaning.
No problems of differential thermal
expansion.
Extensively used for clean tube side
services like steam, gases, BFW.
Used for two-phase mixtures on tube side
to prevent phase separation.
When used with D type front head, gives
very economical design by eliminating
tube sheet and channel at rear end.
18 Sep.2008
 Rear Head Types
W Type (Externally sealed floating
tube sheet)
Also called as O-ring or lantern ring type
Uses lantern ring seals between the floating
tube sheet, shell & channel.
Possibility of leaks at packed joints.
Suitable for low pressure, non-hazardous
fluids on both shell and tube side.
Used for water, steam, air, lube oil.
Design temperature should not exceed 191 C;
limitations on design pressure.
18 Sep.2008
 Shell Types
E Type
One pass on shell side.

Mostly common type – industry standard.

If two or more tube passes are used, then

temperature cross may be a problem.

Temperature cross can be avoided by

using multiple shells in series.

18 Sep.2008
 Shell Types
F Type
Two passes on shell side.
Mostly used with two tube side passes
to ensure true countercurrent flow.
Possibility of fluid leakage through
longitudinal baffle from first pass to
second pass.
Leakage can be controlled by using
lamiflex type seals or by welding the
longitudinal baffle to the shell.
18 Sep.2008
 Shell Types
G Type
Also known as split flow shell.
Low shell side pressure drop can be
achieved.
Has higher temperature efficiency than
E type.
Mostly used as thermosyphon
Reboiler.
Full support plate provided at centre of
shell inlet / outlet nozzles.
18 Sep.2008
 Shell Types
H Type
Also known as double split flow type.
Similar in principle to G type.
Pressure drop is very low (almost one-
eighth of E type).
Mostly used as thermosyphon
Reboiler.
Full support plate provided at centre
of shell inlet / outlet nozzles and at
centre of the shell.
18 Sep.2008
 Shell Types
J Type
Also known as divided flow type.
One shell inlet and two shell outlet
nozzles; variant with two inlet and one
outlet nozzles.
Since half the fluid is flowing through
half the length of the shell, shell side
pressure drop is very low.
Commonly used for low pressure
condensers and other services with
low allowable pressure drop.
18 Sep.2008
 Shell Types
K Type
Also known as Kettle type.
Exclusively used for vaporizing
services.
Tube bundle submerged in pool of
liquid.
Liquid level maintained above tube
bundle.
Vapor disengagement space
provided above tube bundle.
Full tube support plates provided.
18 Sep.2008
 Shell Types
X Type
Also known as crossflow type.
Lowest pressure drop of all shell types.
Used when the shell side volumetric
flow rate is very high and /or allowable
pressure drop is very low.
Mostly used in vacuum condensers.
Full tube support plates are provided.
Proper design to avoid mal-distribution
at shell inlet.
Multiple inlet & outlet nozzles /
distributor plates provided.
18 Sep.2008
 Impingement Protection
Provided to prevent or minimize erosion of tube bundle
components at entrance and exit areas.
An impingement plate or other means of protection is shall
be provided when entrance line values of V2 exceed the
following:
For non-abrasive, single phase fluids 2232 kg/m-sec2
(1500 lb/ft-sec2).
All other liquids, including a liquid at its boiling point
744 kg/m-sec2 (500 lb/ft-sec2).
For all other gases and vapors, including nominally
saturated vapors, and for liquid vapor mixtures,
impingement protection is required.
Shell or bundle entrance and exit V2 should not exceed
5953 kg/m-sec2 (4000 lb/ft-sec2)
18 Sep.2008
 Types of baffles
Single segmental

Double segmental

No-tube-in-window (NTIW)

Disc and doughnut

Helical baffles

RODbaffles

EMbaffles

Grid baffles
18 Sep.2008
 Single segmental baffles
Most common type of baffle.
Also known as segmental baffles.
Baffle cut defined as % of shell ID
(Ds).
Baffle cut: 15% to 45%.
Baffle spacing: 0.2 Ds to Ds.
For a given shell side pressure drop,
fewer baffles are required.
Flow-induced vibration problems may
occur because of larger baffle spacing.
18 Sep.2008
 Double segmental baffles
Alternating arrangement of single piece
& two piece baffle segments.
Baffle cut: 15% to 25%.
Baffle spacing: 0.2 Ds to Ds.
Much lower pressure drop can be
achieved compared to segmental type.
Consequently, baffle spacing can be
reduced.
Lower potential for flow-induced
vibrations.
18 Sep.2008
 No-tube-in-window baffles (NTIW)
Segmental baffles having no tubes in baffle

window region.

Every tube is supported at every baffle.

Eliminates flow-induced vibration problems.

Intermediate tube supports can be provided.

Since all tubes are in cross flow, higher heat

transfer coefficients are achieved.

Higher shell diameters are required.

18 Sep.2008
 Helical baffles
Quadrant shaped baffles, which are
inclined at an angle to the axis of tubes.

Baffles are arranged in such a way that it

results in helical flow pattern.

True plug flow on shell side.

Low pressure drop for a given mass flow

rate because of reduced friction losses

Best suited for services in which shell side

heat transfer resistance is governing and
/or shell side pressure drop or fouling.
18 Sep.2008
 RODbaffles

Developed by Phillips Petroleum Company, USA.

Array of rods are is used as the tube supports.
Four baffles make up one baffle set, which provides tube
support in all four directions for all tubes in the bundle.
Longitudinal flow on shell side.
Pressure drop is low.
Avoid flow induced vibration problems.
18 Sep.2008
 EMbaffles
Proprietary design of M/s EMbaffle BV, The Netherlands.

L&T have collaboration agreement with M/s EMbaffle

Originally designed to reduce shell side fouling..

Tubes supported by Expanded Metal baffles.

Longitudinal flow on shell side (parallel to tubes)

Uniform flow on shell side with no dead zones.

3-D shape of Expanded Metal enhances heat transfer.

18 Sep.2008
 EMbaffles

18 Sep.2008
 Tube Layout Patterns
Tube layout patterns
Square (90 )
Rotated Square (45 )
Triangular (30 )
Rotated triangular (60 )
Square and rot. square layouts used in exchangers requiring
mechanical cleaning on shell side.
For square & rot. square layouts, min. cleaning lane of 6.35
mm to be provided as per TEMA Standards; tube layout
required to be aligned.

18 Sep.2008
 Tube Layout Patterns

Rotated square layout gives higher heat transfer compared

to square layout when shell side flow is laminar.

Rotated square layout may require larger shell diameter

compared to square layout because of alignment of tubes.

Triangular layout gives higher heat transfer and pressure

drop than rot. triangular layout for a given baffle spacing.

18 Sep.2008
 Tube Layout Patterns

Horizontal cut with 30 layout Horizontal cut with 60 layout

18 Sep.2008
 Tube Layout Patterns

Flow Flow
direction direction
Vertical cut with 30 layout Vertical cut with 60 layout

18 Sep.2008
 Stream analysis

‘A’ Stream : Tube-to-baffle leakage stream

‘B’ Stream : Crossflow stream

‘C’ Stream : Bundle bypass stream

‘E’ Stream : Baffle-to-shell leakage stream

‘F’ Stream : Pass partition lane leakage stream

18 Sep.2008
 Effect of baffle cut & spacing

18 Sep.2008
 THANK YOU

18 Sep.2008