Heat Exchanger

Heat Exchanger Introduction

Heat Exchanger Introduction
OUT LINES
• Heat Exchanger Definition, Codes and Standards
• Classification of Heat Exchanger
• TEMA Exchanger Classes
• Heat Exchanger Components
• Baffle Configurations
• TEMA Types
• Types of Bundle Tubes Arrangement
• Flow Streams
• Air Cooler
Heat Exchanger Introduction
Heat Exchanger Definition, Codes and Standards
 Heat Exchanger Definition: A media through which the heat
transfer occurs from one fluid to another across a surface
area.
 Heat Exchanger Design Codes and Standards
 ASME Section VIII
 API 660 - Shell and Tube
 API 661 - Air Cooled Heat Exchangers
 API 662 - Plate and Frame
 Tubular Exchanger Manufacturers Association (TEMA)
Heat Exchanger Introduction
Classification of Heat Exchangers

SHELL& TUBES DOUBLE PIPES PLATES AIR COOLERS

U TUBES INDUCED DRAFT
FLOATING HEAD FORCED DRAFT
FIXED TUBES
Heat Exchanger Introduction
• TEMA Exchanger Classes
 Class R
This class specify design and fabrication of unfired shell and tube heat
exchangers for the generally severe requirements of petroleum and
related processing application.
 Class C
This class specify design and fabrication of unfired shell and tube heat
exchangers for the generally moderate requirements of commercial
and general process application.
 Class B
This class specify design and fabrication of unfired shell and tube heat
exchangers for chemical process services.
Heat Exchanger Introduction
Heat Exchanger Introduction
• Heat Exchanger Components
Heat Exchanger Introduction
Heat Exchanger Introduction
Heat Exchanger Introduction
• Baffle Configurations
Heat Exchanger Introduction
BAFFLES TYPE

DOUBLE SEGMENTAL
SEGMENTAL BAFFLES
BAFFLES
Heat Exchanger Introduction
• TEMA Types
Heat Exchanger Introduction
• TEMA Types
Heat Exchanger Introduction
• TEMA Types
Heat Exchanger Introduction
FRONT HEAD SHELL TYPES REAR END TYPES

A E L

B F M

C G N

N H P
Heat Exchanger Introduction
FRONT HEAD SHELL TYPES REAR END TYPES

D J S

K T

X U

W
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Heat Exchanger Introduction
TEMA AEM TYPE HX

AEM Type exchanger,

FIX Tube sheets design, Front head has a removable cover,
Tube side can be inspected & cleaned without unbolting pipe
works,
Single shell pass & Tube side can be even or single pass
Application: HC liquid cooling & Heating, Condenser application
Heat Exchanger Introduction
TEMA BEM TYPE HX

BEM Type Hex

Popular TEMA model, Front & rear head has integral
covers,
Fixed tube sheet design, tube side can be mechanically
cleaned & inspected,
Heat Exchanger Introduction
TEMA AES TYPE Hex

TEMA AES Type HEx.

Popular TEMA model in refinery application,
Removable bundle,
Tube bundle can be replace later stage, Tube
side & shell side can be cleaned
mechanically, good for differential expansion
between tubes & shell
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Heat Exchanger Introduction
TEMA NEN Type HX

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Heat Exchanger Introduction
HAIR-PIN TYPE EXCHANGER
Heat Exchanger Introduction
Heat Exchangers Types & Properties
TYPE OF DESIGN AEU/BEU AEW/BEW AEP/BEP AES/BES AET/BET CEU NEU BEM, NEN
AEL
Relative Cost
3 6 7 8 9 2 1 5 4
(1 is lowest, 9 is highest)

Removable Bundle Yes Yes Yes Yes Yes Yes No No No

Replaceable Bundle Yes Yes Yes Yes Yes Yes No No No

Removable
Yes Yes Yes Yes Yes No No Yes No
Bonnet/Channel
Chemical/ Chemical/ Chemical/ Chemical/ Chemical/ Chemical/
Tube side Cleaning Chemical Mechanical Mechanical Mechanical Mechanical
Chemical Chemical
Mechanical Mechanical

Chemical/ Chemical/ Chemical/ Chemical/ Chemical/ Chemical/

Shell side Cleaning Chemical Chemical Chemical
Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical

Double Tube sheet Design Available No No No No Available Available Available Available

Number of Tube side

Even Even Even Even Even Even Even Even/Odd Even/Odd
Passes

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Heat Exchanger Introduction
Double Pipe (Multitube) Heat Exchanger

Shell
Side

Tube Side
Heat Exchanger Introduction
FLOATING HEAD
TEMA AES TYPE Hex
CHANNEL
HEAD BONNET
COVER OUT

VENT

CHANNEL
HEAD

TUBE SHELL
SHEET DRAIN
IN
Heat Exchanger Introduction
“U” TUBE
TEMA AEU TYPE Hex

OUT

VENT

DRAIN
IN
Heat Exchanger Introduction
FIXID TUBE
TEMA NEN TYPE Hex

OUT
Tube Bundle is completely welded

DRAIN
IN
Heat Exchanger Introduction
TUBE
Floating Head Heat Exchanger
HEAD CHANNEL
TUBE
COVER HEAD BAFFLE BUNDLE
PLATES FLOATING
HEAD VENT

TUBE DRAIN
SHELL
SHEET
Heat Exchanger Introduction
FLOATING HEAD
Split Rings
DETAILS
Heat Exchanger Introduction
TEST RINGS PACKING
Heat Exchanger Introduction
“U” Tube Heat Exchanger
VENT

DRAIN
Heat Exchanger Introduction
Fixed Tubes Heat Exchanger

VENT VENT

DRAIN DRAIN

Tube Bundle is completely welded

Heat Exchanger Introduction
Re-boiler
Heat Exchanger Introduction
TYPES OF BUNDLE TUBES ARRANGEMENTS

SQUARE TRIANGLE
ARRANGEMENT ARRANGEMENT
TUBES TUBES

COMPRESSED
METALIC GASKET
Heat Exchanger Introduction
Tube Layout Dimensions Flow direction

O
45
O 30

O
60
O 90

34
Heat Exchanger Introduction
Heat Exchanger Introduction
• Flow Streams
 Stream (A): Flow in the clearance between the baffle hole and
the tube.
 Stream (B): Flow through the baffle window.
 Stream (C): Flow in the annular between the Outside Tube
Limit (OTL) and the baffle O.D.
 Stream (E): Flow in the clearance between the baffle and the
shell ID.
 Stream (F): Flow in between the tubes due to the pass
partition.
Heat Exchanger Introduction

VENT

DRAIN
Heat Exchanger Introduction
MAXIMUM PLUGGED TUBES
20% TO 25% OF
PASS TUBES NO.
VENT

DRAIN
Heat Exchanger Introduction
MAXIMUM PLUGGED TUBES
20% TO 25% OF
PASS TUBES NO.
Heat Exchanger Introduction
HYDRAULIC TESTING

Testing fluid

leaking
Tube
Heat Exchanger Introduction
Methods of fluids flow in Heat Exchangers

T1 T1
T2
NOT EFFICIENT AND IS NOT
T2
APPLIED IN INDUSTRY FIELDS t2
t2

t1 t1
PARALLEL FLOW
COUNTER FLOW
Heat Exchanger Introduction
• General Information
 Shell & Tube Heat Exchangers most commonly & widely used heat
exchangers.
 Up to 6000Psig.
 Temperatures to 2000 deg F.
 First Shell & Tube built approx. in 1850.
 Fixed Tube sheet, Floating Head & U-tube type most common.
 Fixed Tube sheets are welded to the shell.
 Floating tube sheets will move in response to thermal & pressure
loads.
 Stationary head is the one where the fluid first enters the exchanger.
 Rear head is the channel or bonnet.
 Fixed tube sheet type are less expensive, clearance between shell
ID & bundle less than floating head exchangers.
 Up to 16 tube passes are feasible, one pass for complete counter-
current low.
Heat Exchanger Introduction
• Disadvantages of Fixed Tube-sheet Exchangers:
 No access to shell side for mechanical cleaning, chemical cleaning
OK.
 Limited access for inspection.
 Difficult & expensive to maintain if corrosion occurs.
 Retubing in place is expensive.
 May require expansion joint in shell to avoid higher stresses
resulting from tube & shell differential thermal expansion.
 Expansion joint often required at start up, shut down or upset
conditions & if steam cleaning is used.
 Cost of expansion joint may eliminate cost advantage.
 High heat transfer coefficient on shell side can eliminate need for
expansion joint.
 Dissimilar metals, consider expansion joint.
Heat Exchanger Introduction
• Floating Head Heat Exchangers (Split ring type):
 Removable bundles, mechanical or chemical cleaning possible.
 No thermal stress problems.
 Easy to replace bundle or shell.
 Hydro test is more complicated as a test ring is required to detect
tube side leaks.
 Shell cover & shell are same diameter.
 Up to 1500 psig pressures.
 Tube bundle can be removed without breaking the shell cover
joints.
 Seal strips needed to reduce shell side by passing.
 Sufficient space provided around the periphery of floating tube
sheet to accommodate the bolting.
 Larger shell diameter required than split ring type.
Heat Exchanger Introduction
AIR
COOLERS

COLD AIR PASS

THROUGH THE FAN

HOT AIR PASS

THROUGH THE FAN
Heat Exchanger Introduction
How to control Fluid Temperature

Variable Angle Louvers

Heat Exchanger Introduction

Louvers Automatic
Controlling gear