Submitted by: Deshbandhu Rawat (0715040017) 4th Year Mechanical

RETUBING OF AMMONIA CONDENSER (E-510)

A CRITICAL HEAT ECHANGER IN AMMONIA DEPT. 20 TPH AMMONIA HANDLED REDUCES TEMPERATURE OF AMMONIA GAS FORM 60OC to 40OC

PROBLEM DETECTION
A leakage of Ammonia Gas was detected in the Ammonia

Condenser (R-510) Major Problem was confirmed and was decided to Investigate and Repair. When checked 22 of the 4478 tubes fitted were either punture, raptured or rusted during its usage.

Shell & Tube type

SIMPLE SHELL & TUBE TYPE DESIGNED MODEL

SHELL & TUBE TYPE

Bonnet Tubesheet Shell Spacers & Tierods Tubes Baffles Shell Nozzle Channel Channel Flange

Channel

Shell Nozzle

Saddles

Drain Plug

Shell Nozzle

FIXED TUBE-SHEET H.E. 1. Simple construction, Low cost, Robust 2. Differential expansion not possible 3. Outside of tubes cannot be cleaned

TYPICAL SHELL-TUBE HE WITH NOMENCLATURE

Pass Partition

DESIGN PRESSURE & TEMPERATURE

Working Fluids

Shell Side: Liquid Water

Safe Working Pressure

Tube Side: Ammonia Gas

Shell Side: 25 kg/cm2

Tested Working Pressure

Tube Side: 6 kg/cm2

Shell Side: 37.5 kg/cm2

Working Temperatures

Tube Side: 9 kg/cm2

Shell Side: -20O to 180O C

Tube Side: 60OC to 40OC

CONDENSER SPECIFICATIONS
Design Vendor

: Snamprogetti, Italy Make : L & T Powai Pressure Vessel Type : Two Pass, Shell & Tube H.E. With Fixed Tubesheet Inside Diameter : 2705 Mm Length Of Vessel : 25000 Mm MOC Of Shell Plates : SA 387 Gr. 22 Class-2 Corrosion Allowance : 1 Mm

CONTINUED
Joint Efficiency
PWHT Insulation Weight Flooded Weight Weight Of Internals

: 100% : Required :160 Mm Thick : 265000 Kg (Approx.) : 398000 Kg (Approx.) : 319471kg (Approx.) : 584471 Kg (Approx.)

(Including Catalyst) Operating Weight

HEAT EXCHANGE ACTION INSIDE TUBES

TEMPERATURE PROFILE- PARALLEL FLOW

TEMPERATURE PROFILE- COUNTER FLOW

DIFFERENT CONFIGURATIONS OF TUBES:

Tubes may be Straight tubes or U bend tubes. Tubes fixed at the ends to Tube-sheets to form Tube-bundles.

Fixing is done either by expanding the tubes in to tube-sheet (called

Tube Rolling) or by expansion & welding. Standard tube patterns are:

Circular

Triangular
Square Triangular pattern (Results in compact design)

If shell side requires mechanical cleaning (as in case of a dirty

fluid), Triangular pattern cannot be used. Pitch- Min. center to center distance between adjacent tubes. Usually at minimum pitches of 1.25 times the tube OD.

FOULING

Deposition of unwanted material on a heat transfer surface.

Fouling the major unresolved problem in heat transfer since 1972 and still same in 2006. Increased capital cost due to larger equipment Additional energy required due to (a) increased pumping (b) reduction in energy recovered Maintenance costs for chemical treatment and cleaning Loss of throughput material Downtime costs

FOULED TUBE BUNDLE

FOULED BUNDLE CLEANING

BEFORE

AFTER

 Fluid velocity high velocity minimizes all modes but requires more pumping power

Wall temperature affects scaling , biofouling, chemical reaction rates

Nature of fluid

Tube material

Related Terms in Exchangers Maintenance:

1. Depressurization / Pressurization 2. Isolation of Exchanger 3. Taper Plugs 4. Soap Solution Test 5. Leaky tubes 6. DPT

7. Thickness Measurement
8. Helium Test / Hydro Test / Pneumatic Test

SOAP SOLUTION TEST

DIE PENETRANT TEST (DPT)

MAINTENANCE DUE TO LEAKAGE:

1. Open the both side end covers of exchanger 2. Cleaning of tubes with Hydro-jet and Nylon brush 3. Leakage Testing of exchangers 4. Plugging out of leaky tubes 5. Replacement & Welding of new tubes

THANK YOU