HEAT EXCHANGERS

Prepared By:

R. P. Verma, SO/C

Modes of Heat Transfers

Conduction:
The heat is transferred in solids due to conduction of heat from

one atom to another atom due to atomic vibration and electrons in motion.

Convection
In convection the heat is transferred in fluid by its molecules in motion.

Modes of Heat Transfers

Radiation
Heat is transferred from one hot object to the other without any transmitting medium in between. Heat is propagated from one hot object to the other in form of electromagnetic waves, which when fall on another object is reconverted into heat.

Conduction

If one end of a iron rod is heated, the other end will also become hot after some time. This is due to conduction. T1 T2

Q k = K.A.(T1-T2)/L

Convection

When water is heated in a pot the heat is transferred due to molecular motion due to density difference.

Q h = h.A.(T1-T2)

T2

T1

Radiation

Heat is transferred from hot body to cold body in form of electromagnetic waves without transferring of medium.

SUN

Q r = . A. T4

EARTH

PRINCIPLE OF HEAT EXCHANGERS

A heat exchanger is a device in which heat is transferred from one fluid to another. The hot fluid gets cooled, and cold fluid is heated. Conduction and convection are the two way which are more concern in case of heat exchangers.

Flow of fluids in HX
Parallel flow

Flow of fluids in HX
Counter flow Type

Flow of fluids in HX
Cross Flow HX

Classification of HXs

Transfer type heat exchangers

Direct contact type heat exchangers Storage type heat exchangers

Transfer Type HX

SHELL AND TUBE TYPE

SPIRAL TYPE

FINNED TUBE TYPE

PLATE TYPE DOUBLE PIPE TYPE

Transfer Type HXs

Shell and tube type

Shell and Tube HX

Consists of bundle of tubes which is suitably fixed with the tube sheet and contained inside the shell. most commonly used HXs in industries. Heat transfers form one fluid to other fluid without coming in to direct contact with each other. The heat exchange takes place by a combination of conduction and convection. Less maintenance and does not required very frequent cleaning. Examples: steam generators, condenser, LP Heaters, Moderator HX, etc.

Classification of heat exchangers

Transfer type HX
Spiral tube type

Spiral tube Type Hx

Usually manufactured in small size. Single piece of tube formed into a spiral and assembled inside the shell. Differential expansion problem eliminated. Constant velocity of fluids and compactness. Due to counter flow the heat exchange capacity get increased.

Classification of heat exchangers

Transfer type HX
Finned tube type HX

Finned tube type HX

Heat transfer area is increased by providing fins over the tubes.
Heat transfer capacity is increased due to large surface area. Such type of heat exchangers are good for high terminal temperature difference.

Plate type HX

PRINCIPLE OF OPERATION

Here heat is transferred from one medium to another through thin metal plates which have been pressed into a special pattern. These plates are separated by special rubber gasket which also seals the liquid flowing through the plates. The holes at the corners of the plates form continuous tunnels or manifolds leading the media, which participate in the heat transfer process, from the inlets into the plate package, where they are distributed into the narrow passage between the plates.

Contd The arrangement pattern of the plates are also special in which they are placed in alternate positions called A & B. A & B plates are similar in all respects and the only difference is in the arrangement of rubber gaskets. The gasket for the plates is mounted in one piece and consists of three ports viz., one field gasket, two ring gasket & few links. The field gasket is a part of the gasket which contain the whole heat transfer area of the plate and two corner openings connected to it and ring gasket seal off the recurring two corners.

Contd
The ring gaskets are connected to field gasket through few short links to make it one piece. Links do not perform any sealing function. They only tie the field & ring gasket together & add some support in certain areas. The gasket is held in place by means of a suitable adhesive thereby preventing it from falling apart.

Advantages of Plate Type HX:

Simple Design Less pressure drop (P) Probability of inter leakage of fluids is very less. Heat-transfer plates are fabricated from SS 304 and 316, titanium, nickel, monel, inconoloy, phosphorbronze and cupro - nickel. Corrugated plate design imparts rigidity to the plates, induces turbulence in the fluids, and assures complete flow distribution. Plates can be easily cleaned and replaced. The heat transfer area can be readily adjusted by adding or subtracting plates. Less Maintenance. Any leak can be easily detected from outside.

FAILURES OBSERVED IN PLATE TYPE HX

Classification of heat exchangers

Transfer type HX Double pipe type HX

Double pipe type HX

Double pipe type HX

Easy to assembled and provides inexpensive heat transfer surface. These are usually assembled in 4, 5,or 7 m effective lengths. When length more than 12 m inner pipe tens to sag and touch the shell causing poor flow distribution. Area available to heat transfer is less. Suitable for high temperature and high pressure applications because of greater strength. Permits true counter flow, which is of particular advantage when very close temperature approaches are required.

Direct type HX

Direct contact type HX

The two fluids mix together and transfer heat by direct contact. Open feed water heaters (Deaerators), desuperheaters, cooling towers and jet condensers are the examples of direct contact heat exchangers. It cannot be used for transferring heat between two gases and two miscible liquids.

Construction and Nomenclature of Shell and Tube Type HX

Nomenclature based on flow direction

FLOW PASS ARRANGEMENT THROUGH THE SHELL AND TUBES

Single-pass tubes and single-pass shell.

FLOW PASS ARRANGEMENT THROUGH THE SHELL AND TUBES

Two-pass tubes and single-pass shell.

FLOW PASS ARRANGEMENT THROUGH THE SHELL AND TUBES

Two-pass tubes and two-pass shell.

FLOW PASS ARRANGEMENT THROUGH THE SHELL AND TUBES

d) Four-pass tubes and two-pass shell.

Components of Heat exchanger

MATERIALS OF CONSTRUCTION
1. TUBES:
Electric-Resistance Welded (ERW) Steel Seamless Steel Copper, Brass, Cupro-Nickel (RAPS Mod. HX tubes) Monel metal, SS, Aluminium, Inconel

2. SHELL:
Carbon Steel, Copper, SS, Aluminium Plates Fabricated from steel pipes Also by rolling steel plate

3. TUBE SHEETS:
Carbon Steel cladded with same material of tube. Naval Brass. SS. Cupro-Nickel.

4. CHANNELS & COVERS:

Mild Steel & Cast Iron for mild process conditions. For corrosive fluids Copper, Monel, SS or any other materials lined on MS are used.

5. GASKETS:
Compressed Asbestos, rubber or metallic gaskets are used.

Tube Pitch Layout of HXs

Different Types of Shell and Tube HX

Fixed tube sheet HX with integral channels

Pull through floating head 1-2 pass HX Split ring floating head 1-2 pass HX U-bend heat exchangers.

Fixed tube sheet HX with integral channels

Pull through floating head 1-2 pass HX

Split ring floating head 1-2 pass HX

Split Ring Assembly

U-bend heat exchangers

OPERATION OF HX
Open the vent connections & start to circulate cold medium only. Ensure that the passages in HX are filled with the cold fluid before closing the vent. Now gradually introduce the cold medium till all passes are filled with the liquid or vapour, as the case may be. Then close the vent & slowly bring the unit up to temperature. Always start operations gradually. Do not admit hot shock to HX suddenly when empty/cold. Do not shock the unit with cold fluid when unit is hot.

SHUTTING DOWN
Hot fluid to be shut-off first. Keep the cold medium in circulation till the temperature of HX comes down to safe limits. All fluids to be drained to minimise the possibility of freezing & corrosion. Guard against water hammers. Minimise retention of water after draining the tube side of water cooled HXs by blowing out with dry air.

Performance of a Heat Exchanger

Basic Heat Transfer Equation Q = U . A . T = U . A. (T h T c) Where: U = Overall heat transfer coefficient A = Heat transfer surface area T h = Temperature of hot fluid element T c = Temperature of cold fluid element

Factors affecting performance

Start up Reduced Thermal performance

Blockage of flow Fouling on tubes Improper venting Operation beyond design specifications Tube wall or tube sheet leaks

Thermal stresses Excess heat exchanger capacity Vibrations

MAINTENANCE OF HX

A marked increase in pressure drop & reduction in performance indicates about fouling/scaling. Remove scaling at regular intervals by cleaning. Locate leaks in tubes & joints between tubes & tube sheets. Tube bundle removal for cleaning shell & tube bundle or replacement of tube bundle. Tube bundle cleaning: chemical & mechanical cleaning methods. Tube expanding: to tighten leaky rolled tube joints. Replacement of gaskets.

CLEANING METHODS

CIRCULATING LIGHT DISTILLATE/HOT WASH OIL THROUGH TUBES/SHELL AT HIGH VELOCITY WILL EFFECTIVELY REMOVE SLUDGE OR SIMILAR SOFT DEPOSITS. SOME SALT DEPOSITS MAY BE WASHED OUT BY CIRCULATING HOT FRESH WATER. HIGH PRESSURE WATER JET CLEANING. USE OF COMMERCIAL COMPOUND. USE OF SCRAPPERS OF ROTATING WIRE BRUSHES OR OTHER MECHANICAL MEANS.

HYDRSTATICS OF HX

Hydrostatically tested with water & held at test pressure for 30 minutes. The shell & tube sides are tested separately so that leaks in tube joints can be detected from at least one side. If tube design pressure is higher, the bundle is tested outside the shell only if specified. Weld joints are to be properly cleaned prior to testing. The hydrostatic test pressure is 1.5 times the design pressure at room temperature. Correction factor is the ratio of allowable stress value for test temperature of vessel to the allowable stress value for design temperature. Up to 650 F this value is unity.

Inspection and testing

Visual inspection Eddy current testing Ultrasonic testing Radiography Liquid penetrate testing Magnetic particle testing Pressure leak testing

Any Question ?