PRESENTATION

ON
MAINTAINCE OF HEAT
EXHANGERS

PRESENTED BY:
HAMMAD MAJEED
CHEM ENGG. DEP
NFC IEFR F
 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 260°C).
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 centre-
centre 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. SHE’s 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
to 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.
 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…