PRESENTATION ON MAINTAINCE OF HEAT EXHANGERS PRESENTED BY: HAMMAD MAJEED CHEM ENGG.

DEP NFC IEFR F PAKISTAN

HEAT EXHANGERS
Heat exchanger is a device built for efficient heat transfer from one medium to another. The medium may be separated by a solid wall, so that they never mix, or they may be in direct contact. They are widely used in , industry ,refrigeration, air conditioning, power plants chemical plants, petrochemical plants petroleum refineries and natural gas processing.

TYPES
Shell and tube heat exchanger Plate type heat exchanger Spiral tube heat exchanger Co-centric tube heat exchanger Lamella type heat exchangers Regenerative heat exchanger Plate fin heat exchanger

SHELL N TUBE EXCHANGERS

SHELL N TUBE EXCHANGERS

Shell and tube heat exchangers consist of a series of tubes. One set of these tubes contains the fluid that must be either heated or cooled. The second fluid runs over the tubes that are being heated or cooled so that it can either provide the heat or absorb the heat required. A set of tubes is called the tube bundle and can be made up of several types of tubes: plain, etc. Shell and Tube heat exchangers are typically used for high pressure applications (with pressures greater than 30 bar and temperatures greater than 260C).

CONTD

CONTD

CONTD.
There are several thermal design features that are to be taken into account when designing the tubes in the shell and tube heat exchangers. These include , Tube diameter: Using a small tube diameter makes the heat exchanger both economical and compact. However, it is more likely for the heat exchanger to foul up faster and the small size makes mechanical cleaning of the fouling difficult. To prevail over the fouling and cleaning problems, larger tube diameters can be used.

CONTD
Tube thickness:
The thickness of the wall of the tubes is usually determined to ensure: That flow-induced vibration has resistance Axial strength Availability of spare parts Hoop strength (to withstand internal tube pressure) Buckling strength (to withstand overpressure in the shell)

CONTD
Tube length:
Heat exchangers are usually cheaper when they have a smaller shell diameter and a long tube length. Thus, typically there is an aim to make the heat exchanger as long as physically possible whilst not exceeding production capabilities. However, there are many limitations for this, including the space available at the site where it is going. etc

CONTD
Tube pitch:
when designing the tubes, it is practical to ensure that the tube pitch (i.e., the centrecentre distance of adjoining tubes) is not less than 1.25 times the tubes' outside diameter. A larger tube pitch leads to a larger overall shell diameter which leads to a more expensive heat exchanger

PLATE TYPE HEAT EXCHANGER

PLATE TYPE HEAT EXCHANGER

CONTD..
The plate and frame heat exchanger was one of the first compact exchangers to be used in the UK process industries, being originally introduced in 1923; the first plates were made of gunmetal. It is currently second to the shell and tube heat exchanger in terms of market share. The most common variant of the plate and frame heat exchanger consists of a number of pressed, corrugated metal plates compressed together into a frame. These plates are provided with gaskets, partly to seal the spaces between adjacent plates and partly to distribute the media between the flow channels. The most common plate material is stainless steel.

FLOW PATTREN

PROS N CONS
Gas keted units may be used in refrigeration and heat pump plants Extensively used in the processing of food and drinks, In the chemicals sector, a substantial list of heating and cooling applications includes cooling iso paraffin, sulphuric acid, salt solutions, hexane and kerosene. Heating glycerine and condensing ethanol are other routine uses. The offshore Care should be taken in locating the gaskets during reassembly, as imperfect sealing is the main disadvantage of the plate and frame heat exchanger.

SPIRAL TUBE HEAT EXCHANGER

SPIRAL TUBE HEAT EXCHANGER

A spiral heat exchanger (SHE), may refer to a helical (coiled) tube configuration, more generally, the term refers to a pair of flat surfaces that are coiled to form the two channels in a counter-flow arrangement. Each of the two channels has one long curved path. A pair of fluid ports are connected tangentially to the outer arms of the spiral, and axial ports are common, but optional.

FLOW PATTREN
Spiral Flow/Cross Flow One fluid is in spiral flow and the other in a cross flow. Spiral flow passages are welded at each side for this type of spiral heat exchanger. SHEs are generally smaller than other types of heat exchangers. The display or the pattern view is in the next slide

CONTD.

PROS N CONS
The main advantage of the SHE is its highly efficient use of space The SHE is good for applications such as dry milk products, In heat recovery, pre-heating and effluent cooling. For sludge treatment,

CONTD..
Fouling occurs when a fluid goes through the Spiral heat exchanger, and the impurities in the fluid precipitate onto the surface of the tubes. Precipitation of these impurities can be caused by: Frequent use of the heat exchanger Not cleaning the heat exchanger regularly Reducing the velocity of the fluids moving through the heat exchanger

CO CENTRIC TUBE HEAT EXCHANGERS

CO CENTRIC TUBE HEAT EXCHANGERS

Co centric tube heat exchangers also known as double pipe exchangers widely used in industry for the exchange of heat. There are two main flow pattern in double pipe heat exchangers Co current Counter current

FIG

CONTD
Both of these patterns follow in the same heat exchanger In b/w stem and cold water there is a co flow In b/w hot water n cold water there is a counter current flow.

LAMELLA HEAT EXCHANGER

LAMELLA HEAT EXCHANGER

The lamella heat exchanger is an efficient, and compact in size, heat exchanger. The principle was originally developed around 1930 by the company Ramens Patenter Normally consists of a cylindrical shell surrounding a number of heat transferring lamellas. The design can be compared to a tube heat exchanger but with the circular tubes replaced by thin and wide channels, lamellas.

FIG

FIG

PROS N CONS
Lamella exchanger is widely used for small scale Have an extensive use for sensitive fluids. Less pressure drop then others. No baffles in it so turbulence is small. As no baffle so rate of H.T is low.

MAINTAINCE PROCEDURE

MAINTAINCE
Minor maintenance
When the heat exchanger is isolated, minor maintenance such as clearing blockages, cleaning, lubrication, and oil level checks can be carried out in accordance with the Standard Operating Procedures and the Permit To Work system

CONTD
Cleaning
For a heat exchanger to work efficiently, the heat transfer surfaces must be clean, and the flow passages must be clear of obstruction. A cleaning program should be put in place to help insure the continued optimal, or near optimal, performance of heat exchangers.

CONTD
Mechanical cleaning
Mechanical cleaning requires opening the exchanger. This involves the removal of the end covers and the tube bundle (plates in the case of a plate exchanger), then cleaning and then reassembly. Damage of the exchanger components, particularly the tube bundle, is always a risk and great care must be taken .

CONTD
Chemical cleaning
With chemical cleaning it is important to identify the deposit in order to select the correct method for its removal. Some of the common chemicals used to clean exchangers are: Mineral acids Organic acids Alkaline agents Organic solvents

MINEARL ACIDS
Hydrochloric acid is most widely used because of its low cost. It dissolves calcium carbonate (limestone) scale deposits. (If sulphuric acid was used to remove calcium carbonate scale, calcium sulphate would form this is another insoluble substance). Otherwise, this would result in the formation of calcium sulphate, another equally insoluble substance.

ORGANIC ACIDS
Citric and formic acids are widely used especially in shell n tube where chlorine ions would cause problems with austenitic steels. Citric acid is used, in the form of ammonium acid citrate, to prevent the formation of insoluble ferrous acid citrates.

ALKALINE AGENTS
These agents have a detergent action and are capable of neutralizing acids. Some examples are: soda ash, caustic soda, sodium silicates and tri-sodium phosphates

ORGANIC SOLVENTS
These are used where fouling is due to waxes and tars. They include kerosene , diesel fuels and tri chloro -ethane. Organic solvents do not dissolve mineral deposits

HOW TO CLEAN THE TUBES

When removing tube bundles from heat exchangers for inspection or cleaning, exercise care to see that they are not damaged by improper handling. Do not handle tube bundles with hooks or other tools which might damage tubes. Move tube bundles on cradles or skids.

CONTD
Insert a soft wood filler board between the bearing plate and tubes heat face prevent damage to the tube ends. A hardwood spreader block must be inserted between the cable and each tube sheet to prevent damage to the tube ends.

to

CONTD
Lift tube bundles horizontally by means of a cradle formed by bending a light gauge plate or plates into a Ushape. Make attachments in the legs of the U for lifting. Do not drag bundles, of tubes n coils of spiral plated to avoid any damage.

CONTD
Extensive care is needed in the case of lamella b/c the lamella leafs are very sensitive and not structurally strong. Do not attempt to clean tubes by blowing steam through individual tubes. This overheats the individual tube and results in severe expansion strains and leaking tube-to-tube sheet joints.

SOME MORE

TIGHTENING OF LEAKING FLANGES

It is preferable, if possible, to replace the gasket as the cost of the gasket relative to the leak is minor. If a gasket needs to be replaced, the flow line will need to be depressured, isolated and drained before work. If it is not possible to replace the gasket, the flange can be tightened by:

CONTD
checking the alignment of the flange to see that the two flange faces are parallel reducing the tension on the flange bolts so that when the flanges are tightened In shell n tube and double pipe rare and front ends bolts should be tighten properly. In spiral tube the coils joints should be checked and tighten properly

TEMPRATURE SHOCK
Temperature shock is one of the most failure cause in exchangers due to the exceeded pressure of steam so steam valve should be checked and maintained properly to avoid damage.

SLUGISHNESS
Do not thread rods or cables through tubes of a heat exchanger equipped wit ITT Standard Amatran tubes, or any with internal fins. Do not remove channel covers, shell covers, floating head covers or bonnets until all pressure in the heat exchanger has been relieved and both shell side and tube side are completely drained.

MAINTAINCE CIRCLE FOR P T E

The most important part in plate type exchanger is the gaskit If there is a problem with it then whole process damaged. Replacement circle for gas kit is