Analysis of Heat exchangers

Efficient heat exchange

comes in various forms

Akshay Kr Mishra
Sharda University
MECH , 4 YR.
Types of heat exchanger

Parallel flow Diagonal flow

Acc. To
fluid flow

Counter flow Cross flow

 Counter flow

Cross flow Diagonal flow

RadiatOR tyPe HXs (RHe)
AIR to WATER heat
exchanger.
Uses fans to circulate air
and cool the fluid inside
tubes of HXs.
Cooling medium is
AIR.
Radiator is made via
Al alloy.
Working of a radiator type HX
HOw tO MaiNtaiN RHes
Feed the oil from inlet only.

Flush clean the radiator with

pressurized air once in a week, to
maintain proper air flow.

Dont keep any obstacle in front of

radiator which may obstruct the air
flow.
DAIKIN 90507; TRACTOR PLANT( M/C SHOP)

DAIKIN 80017; TRACTOR PLANT( M/C

SHOP)
DSL 50; AXLE PLANT(STEERING KNUCKLE LINE)

HH5C-PLC; AXLE PLANT( STEERING KNUCKLE L

#50604 HELLER MCH300; BKW HX; TRACTOR PLANT( M/C
 Applications of RHE
Forced air heating & cooling
Indoor & outdoor wood furnaces/stoves/boilers
Heat pumps
Chilled water cooling
Permanent aluminum fin to copper coil bond ensures
superior heat transfer properties
Cooling towers
Heat withdrawn from water via contact between
the water and the air.
Heat exchange is b/w air and water and through
the evaporation of a small part of the water that
needs to be cooled.
It allows to cool down to a temperature lower
than the ambient temperature, which is an
important advantage compared to dry coolers.
A regular maintenance will also minimize the risk
of legionella.
Cooling tower, utility area
Plate type HXs (PHE)
Constitutes of 2 plates fix frame plate and
pressure plate(movable).
Pack of corrugated metal plates with portholes for
passage of 2 fluids b/w which Heat transfer takes
place.
These plates are fitted with gasket which seals the
inter plate channel and directs the fluids into alt.
channels.
Principle of PHE
Channels are formed b/w the plates & corner ports are
arranged so that the media flows through alt. channels.
Heat transferred via plate b/w channels & complete
concurrent flow is made for highest possible efficiency.
Corrugation of plates provides passage b/w plates, support
each plate against adjacent one and enhances the turbulence,
resulting in efficient heat transfer.
CHESSISE PHE; AM 10 FM1; TRACTOR PLANT (PAINT SH
defects

Leakage in plate heat exchanger

CALCIUM SULPHATE SCALING IRON FOULING
 HOw tO MaiNtaiN PHes
Back flush the PHE once a week.
check the PHE for leaks, especially during intense running
periods.
Check Regularly the gaskets as soon as possible for softness &
elasticity, as brittle gaskets are no good.
Install a water cleaning system. It will soften the water & will
prevent hard scaling and fouling from coating the plates. Even
chlorination should be proper.
 Effective Heat Transfer- Large surface areas and
corrugated plates allow Plate heat exchangers to transfer
heat very efficiently.
Easy Maintenance
Compact Design
Cost-efficient- PHE are smaller and use less material to
produce.
Materials- PHE are available in a wide variety of
materials. Plates are available in: Stainless Steel,
Titanium, Titanium-Palladium, Nickel etc. as per our
requirement.
 Types of PHE

Gasketed PHE Semi-welded PHE

Welded PHE
1.Gasketed PHE -use high quality gaskets and design to seal
plates together and protect against leaks.
Plates can easily be removed for cleaning. expansion, or
replacing purposes, drastically reducing maintenance costs.
Applications include - Chemical, HVAC etc.

2.Welded PHE - Here plates are welded together. Extremely

durable, ideal for transferring fluids with high temperatures or
corrosive materials.
Mechanical cleaning of plates is not an option as with PHE due
to welding. Applications include- Hazardous liquids , oil cooling
3.Semi-welded PHE A mixture of welded and gasketed
plates.
Contains pairs of two plates welded together which are then
gasketed to other pairs
Easy to service on one side and able to transfer more intense
fluids on the other.
They are perfect for transferring expensive materials
since they have a very low risk of fluid loss.
 Extreme temperature difference b/w 2 fluids-its
limitations
generally more cost efficient to use a Shell & Tube
heat exchanger . As in a Plate heat exchanger, there
can be a high pressure loss due to the large amount of
turbulence created by the narrow flow channels.

Gasketed Plate Heat Exchangers are limited in high

fluid temperatures, by the temperature limitations of
the gasket.
 BHE is a compact variation of PHE but does not have
carbon steel frame, gaskets or tightening bolts.
It simply has AISI 316 stainless steel corrugated
BHE

channel plates and the heat exchangers are brazed in a

vacuum furnace and helium pressure tested to ensure
leak-free performance.
No pressure retaining parts such as shell of a shell and
tube type etc.
This combination with maximum heat transfer and
high efficiency make it the most efficient HX.
WORKING OF BHE
EXPLODED VIEW OF BH
GEA MAKE BHE;AXLE PLANT

Top view of BHE; GEA MAKE; AXLE PLA

 OPERATING PRINCIPLE
Based on the plate and nozzle orientation, each fluid passes
through alternative channels within the heat exchanger. All
plate material and nozzles are of Stainless Steel 316.
An extremely high heat transfer coefficient is attained due
to the flow characteristics in each channel. A specially
designed and tested chevron pattern causes a turbulent flow
of the fluid resulting in higher heat transfer.
 TYPES OF BHE
TPL SERIES- In case of media with average viscosity and high
viscosity. The TPL unit has special turbulators placed between
the flow of gaps and by diagonal media flow together with large
diameter connections very high heat exchangers rates are
reached.
GPL SERIES- Heat transfer plates with V-corrugation for
universal application in case of media with low velocity. GPL
series has thermally optimized plate corrugation which produces
highly turbulent flow even in case of low mass flow.
TPL SERIES GPL SERIES
CB-COPPER BRAZED HX
These heat exchangers from the smallest unit CB14, to the
largest unit CB300, are brazed with 99.9 % copper.
This forms a self-contained unit that can handle both high
pressures and high temperatures.
The exceptional heat transfer efficiency makes all CB units
very compact. As a result, they can tackle large-capacity duties
even though there is only limited installation space available.
CB- COPPER BRAZED HX
 Fusion bonded PHE
AlfaNova, the worlds first 100% stainless steel AND
fusion brazed plate heat exchanger,
Extreme temperature and pressure fatigue conditions that
would destroy a conventional brazed heat exchanger are no
match for the rugged AlfaNova.
compact, high-performance AlfaNova offers levels of
hygiene and corrosion-resistance unmatched by any
other BHE or any HX.
ALFANOVA- FUSION BONDED PHE
 ADVANTAGES OF BHE
High corrosion resistant- All plates uses SUS316 material.
High pressure resistant
High thermal efficiency
High working temperature- Brazed Plate Heat Exchanger's
SUS316 material structure offers higher working temperature
range up to 200.
Compactness
Low maintenance- The corrugated plates are designed to
achieve turbulence flow at a low flow rate, thus decreasing
the need for frequent maintenance.
 HOw tO MaiNtaiN BHes
For heavier fouling use chemicals such as formic
acid, citric acid in concentration compatible with
copper.
Use CIP(cleaning in place) systems to chemically
remove calcium deposits and other forms of scaling
from different plate surfaces.
Do not leave the unit on standby after cleaning.
Do not use liquids that are corrosive to stainless
steel or brazing material(Cu or Ni).
sHeLL & tuBe tyPe HXs
Water to water heat exchanger

consists of a shell (a large pressure vessel) with a

bundle of tubes inside it. One fluid runs through
the tubes, and another fluid flows over the tubes
(through the shell) to transfer heat between the
two fluids.
 Tube pitch- The shortest distance between centers of two
adjacent tubes is called the tube pitch, should not be less
than 1.25 times the tube diameter.
Baffles- Responsible for obstructing and redirecting the
flow of fluid in the shell side of an exchanger.
Situated normal to the walls of the shell and force the
liquid to flow at right angles to the axis of the tubes Thus
increasing turbulence resulting in greater heat transfer.
Exploded view of shell and tube heat exchanger
Yantra make HX ; shell and tube type; TRACTOR PLANT( ENGINE SHO
Shell and tube type HX in diesel generators; utility area
 How to Maintain shell & tube HX
At regular intervals , an examination should be made of internal
as well as external of HX.
Intervals b/w cleaning should not inc. because difficulty of
cleaning will inc., as scaling or deposits on tubes will inc.
Before disassembly, make sure that unit has been depressurized,
vented and drained of all hazardous materials purged.
Circulate hot wash oil and hot water with high vel. to remove
sludge and salt deposits from tubes.
 Forced draft ventilation

Controls indoor air quality.

Excess humidity, odors &
contaminants controlled via
dilution or replacement with
outside air.
Ventilation includes both the
exchange of air to the outside
as well as circulation of air
within the building.
Analysis of HXs used in
CNH(Case New Holland)

4 types of HXs are being

used in CNH
Shell &
RHE PHE Tube BHE
type
 MACHINE RADIATOR type
SHOP HXs

PLATE type
PAINT SHOP
HXs
TRACTOR
PLANT
SHELL & TUBE
ENGINE SHOP
type

NEW DRIVE
BRAZED HXs
LINE (NDL)
CNH
MACHINE
BRAZED HXs
SHOP

DIFFERENTIAL
LINE
AXLE PLANT
STEERING
RADIATOR
KNUCKLE
type HXs
LINE

PLANET
CARRIER LINE
 4%
RHE
9%
PHE

7% BHE
SHELL & TUBE
COOLING TOWER
12%

68%

PIE CHART SHOWING HX DISTRIBUTION

TOTAL NO. OF HEAT EXCHANGERS IN CNH- 71

NO. OF RADIATOR TYPE HX - 46

TRACTOR PLANT -27
AXLE PLANT 16
UTILITY AREA- 3
NO. OF PLATE TYPE HX- 8
COOLANT TOWER- 6
NO. OF BRAZED TYPE HX- 5
NO. OF SHELL &TUBE TYPE HX- 6
TRACTOR PLANT- 2
UTILITY AREA - 4
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs
RHE TRACTOR MACHINE #533 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #682 DAIKIN 90507
MAKINO
A77
RHE TRACTOR MACHINE #615 DAIKIN
MAKINO
A81
RHE TRACTOR MACHINE #534 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #683 DAIKIN 40807
MAKINO
A77
RHE TRACTOR MACHINE # 195 DAIKIN
MAKINO
A81
TRACTOR MACHINE #50437 BKW
HELLER
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs
RHE TRACTOR MACHINE #441 DAIKIN
MAKINO
A81
RHE TRACTOR MACHINE #352 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #685 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #485 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #351 DAIKIN
MAKINO
A81
RHE TRACTOR MACHINE #456 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #533 DAIKIN 80017
MAKINO
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs
RHE TRACTOR MACHINE #440 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #485 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #634 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #684 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #456 DAIKIN
MAKINO
A77
RHE TRACTOR MACHINE #607 DAIKIN
MAKINO
A81
RHE TRACTOR MACHINE #352 DAIKIN
MAKINO
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs
SHELL AND TRACTOR ENGINE ENGINE YANTRA
TUBE TYPE SHOP ASSEMBLY
TEST CELL 4
RHE TRACTOR MACHINE #50604 BKW WRK10/2R2
SHOP HELLER 8-CH2
MCH 300

RHE TRACTOR MACHINE #50603 BKW WRK10/2R28

SHOP HELLER -CH2
MCH 300

RHE TRACTOR MACHINE #50437 BKW WRK10/2R28

SHOP HELLER -CH2
MCH 300

RHE TRACTOR MACHINE #50239 BKW WRK10/2R28

SHOP HELLER -CH2
MCH 300

RHE TRACTOR MACHINE #50240 BKW WRK10/2R28

SHOP HELLER -CH2
MCH 300
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs
PHE TRACTOR PAINT SHOP CHESSISE Alfa laval AM 10 FM1
PHE
PHE TRACTOR PAINT SHOP PRE Alfa laval P2FL1 (OLD)
DEGREASIN
G TANK
NO.1
PHE TRACTOR PAINT SHOP DEGREASIN Alfa laval P2FL1
G-1 TANK
NO. 2
PHE TRACTOR PAINT SHOP DEGREASIN Alfa laval P2FL1
G-2 TANK
NO. 3
PHE TRACTOR PAINT SHOP PHOSPHATE Alfa laval P2FL1 (OLD)
TANK NO. 7
PHE TRACTOR PAINT SHOP PHOSPHATE Alfa laval M6-MFG
TANK NO. 7 (NEW)

PHE TRACTOR PAINT SHOP CED BATH Alfa laval P2FL1

TANK NO. 11
PHE TRACTOR PAINT SHOP PRE Alfa laval M6-mfg
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs
BRAZED TRACTOR NDL (NEW NDL M/C 1 FUNKE
HXs DRIVE
LINE)
BRAZED TRACTOR NDL (NEW NDL M/C 2 FUNKE
HXs DRIVE
RHE AXLE DIFFERENT BEMCO WARKIN
LINE)
IAL LINE
RHE AXLE DIFFERENTI HIND GK ENGG. HH5C-PLC
AL LINE HH473-11797
RHE AXLE STEERING BEMCO WARKIN DSL 50
KNUCKLE 20Ton
LINE
RHE AXLE STEERING HIND 5Ton GK ENGG. HH5C-PLC
KNUCKLE
LINE
RHE AXLE STEERING BEMCO WARKIN DSL 50
KNUCKLE 20Ton
LINE
RHE AXLE STEERING BEMCO WARKIN DSL 50
KNUCKLE 20Ton
LINE
TYPE OF PLANT LINE/SHOP M/C NAME MAKE OF MODEL/TY
HXs HXs PE OF HXs

RHE AXLE PLANET BEMCO WARKIN DKL 307

CARRIER 40Ton
LINE
RHE AXLE PLANET BEMCO WARKIN DKL 307
CARRIER 40Ton
LINE
RHE AXLE MACHINE MAC 6290 YUKEN
SHOP MAKINO
A100E
RHE AXLE MACHINE MAC 11173 YUKEN
SHOP MAKINO
A100E
RHE AXLE MACHINE MAC 6291 YUKEN
SHOP MAKINO
A100E
RHE AXLE MACHINE MAKINO YUKEN
SHOP A81

RHE AXLE MACHINE MAKINO YUKEN

SHOP A81
TYPE OF PLANT SHOP MACHINE MAKE MODEL
HX NAME

RHE TRACTOR DRIVE LINE #50525 BKW WRK10/2R2

HELLER 8-CH2
MCH 300

RHE TRACTOR DRIVE LINE #50237 BKW WRK10/2R2

HELLER 8-CH2
MCH 300

RHE TRACTOR DRIVE LINE #51276 BKW WRK10/2R2

HELLER 8-CH2
MCH 300

BHE AXLE M/C SHOP FAMAR GEA WP 1-24E

ERGO 500

BHE AXLE M/C SHOP FAMAR GEA WP1-24E

ERGO 500

BHE AXLE M/C SHOP FAMAR GEA WP 1-24E

ERGO 500
Contingency plans

Radiator type HX
MODES OF PRECAUTIONS
FAILURE CONSEQUENCES 1. Make sure that
1. Radiator gets radiator is cleaned
1.No proper air once in 2-3
choked/jammed flow , oil will take months.
2. Fan of RHE time to get cooled,
stops working. leading to 2. Keep the fan as a
accumulation of spare part with
heat & eventually you.
m/c will go down.
Radiator type HX
 BRAHMASTRA FOR PHE
When the level of problem is at a level where above
written precautions dont work then use
BRAHMASTRA that is contact the vendor. And here
its ALFA LAVAL.

NAME: ALFA LAVAL INDIA LTD.

ADDRESS: 704-705,Ansal bhavan,16, Kasturbha
Gandhi Marg , Delhi
PHONE NO: 01141293300
EMAIL ID: india.info@alfalaval.com
 Brahamastra for BHE
well it does not have any modes of failure except that it stops
working, so in that case is contact the vendor. And here its
FUNKE and GEA.

NAME: Funke heat exchangers India pvt ltd.

ADDRESS:14, Hadapsar Industrial estate, Hadapsar, Opposite
Kwality bakery,Pune.
CONTACT PERSON: Ashish B Kale
PHONE NO:02066047894,9403961354
EMAIL ID: info@funke.co.in
NAME: GEA Ecoflex India Pvt Ltd.
ADDRESS: R-493, MIDC, TTC Industrial Area, Rabale
400701 Navi Mumbai
India
CONTACT PERSON: Virendra Jhamb
FAX: +91 22 27693797
EMAIL ID: virendra.jhamb@geagroup.com
 Ways to
Knowing
eliminate Safety
danger
danger
Universal
 HAZARDS INVOLVED PREVENTIVE
While cleaning the plates; METHODS
scaled or fouled deposits Use Goggles
PHE

may come flying right into

ones eyes.
Use protective masks
Hot gases may leak while
cleaning which forms CO
when mixes with
surroundings.
SHELL & TUB
THANK YOU