INSPECTION OF HEAT

EXCHANGERS

AT CONFERENCE HALL ON

Presented by Mr.

For the benefit of business and people

1
 1 What is HE.
2 Thumb rules
3 Introduction
CONTENTS 4 Tube Sheet Details
5 Tube To Tube Sheet Joint
6 Tube Sheet To Tube Sheet Joint
7 Requirement Of Mock Up
8 Mock Up Testing
6.1 DIM. Report of Mock Up
6.2 Expn. Record of Mock Up
6.3 Pull Out Record of Mock Up
9 Problems Incurred
10 Customers Concurrence
11 Conclusion 2
1

INFORMATION ON

HEAT EXCHANGERS

3
1 HEAT EXCHANGERS DOUBLE TUBESHEET EXCHANGERS
What is HE?

What is Heat Exchanger ?

A heat exchanger is a device built for efficient HEAT transfer from one fluid to another,
whether the fluids are separated by a solid wall so that they never mix, or the fluids are
directly contacted.

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HEAT EXCHANGERS
Where

Where heat exchangers used ?

They are widely used in refrigeration , air conditioning, space heating,

power production, and chemical processing. One common example of a heat exchanger
is the radiator in a car, in which the hot radiator fluid is cooled by the flow of air over the
radiator surface.

5
 codes

CONSTRUCTION CODES :

SHELL,CHANNELS,BONNETS,COVER AND FLANGES: ASME SEC VIII DIVI

WITH TEMA RECOMMENDATIONS IF ANY

TUBE SHEETS & OTHER PARTS : TEMA

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 Clasification

CLASIFICATION OF HES

CLASS R : PETROLEUM/REFINERY APPLICATIONS

CLASS C : COMMERCIAL AND GENERAL PURPOSE

CLASS B : CHEMICAL PROCESS APPLICATIONS

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 HEAT EXCHANGERS types

TYPES OF HEAT EXCHANGERS

Heat exchangers may be classified according to their flow arrangement

FOLLWING ARE SOME EXAMPLES ::::

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 Heat exchangers Parll flow

Parallel-flow Heat Exchanger

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 Counter flow

Counter-flow Heat Exchanger

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 Cross flow

CROSS FLOW HEAT EXCHANGER

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 HE - PARTS parts

SHELL (MAIN AND CHANNEL)

TUBE SHEET
TUBES
BAFFLES
TIE RODS AND SPACERS
IMPINGEMENT PLATE
DISH ENDS
BY PASS SEALING STRIPS
LIFTING LUGS
GASKETS

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 1 HEAT EXCHANGERS
Documents
Douments review

1) Douments review :

Valid document means it is a document Approoved/Endorsed by the Authorised person only

Purchase order
Drawings
Quality assurance plan
Reference Specifications mentioned in above documents

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 1 HEAT EXCHANGERS DOUBLE TUBESHEET EXCHANGERS
RM Insp 1

Raw Materials :

Plates for shells

Forgings
Tubes
Welding/Overlay consumables
Tie rods
Spacers
Structurals

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 2 HEAT EXCHANGERS
RM Insp 2
THUMB RULES IN STREAM ALLOCATION

Inprocess Inspection

Raw material Identification :

A. Check Correlation with Original MTC and Identify all items before cutting at
appropriate place, so that details are available/visible permanently. Example:
for shell material identify inside, for tube sheet and flanges identify on OD.

B. In case of no co relation with MTC, ask for check testing. Identify check test
number on both sample and on Job also.
C. Check for NDT requirement during raw material stage.
D. Check for dimensions like thickness, diameters etc.,

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3 HEAT EXCHANGERS INTRODUCTION

SHELL : DESIGNED SHELL DIA SHALL BE WITHIN TEMA LIMITATIONS

TOLARANCE ON INSIDE SHELL DIA :

PIPE SHELLS : AS PER MATERIAL ASTM SPECIFICATION

PLATE SHELLS : ACTUAL I.D. NOT TO DEVIATE BY DESIGN I.D , +3.2 MM

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TUBES
TUBES

GENERAL TUBES SHALL BE COLD DRAN AND SEAMLESS

-MINIMUM U TUBE BEND RADIUS SHALL BE 1.5 TIMES O.D.
-Flattening of tube at bend( shall not exceed 10%)
-General HT IS annealing for CS and SS pipes and annealed and tempered
for cupper tubes
- unless otherwise specified given wall thickness of tube is minimum thick.

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2 TUBE SHEETS
Tube sheet 1

o OVERLAY REQUIREMENTS (CORROSION AND CHEMICAL PROTECTION)

o CHECK FOR OVERLAY THICKNESS
o NDT OF OVERLAY : PT FOR SURFACE DISCONTINUITYS AND UT FOR BONDING
AND OVERLAY WELD DISCONTINUITYS
o DIMENSIONS : CRITICAL GROOVE DIMENSIONS AS PER TEMA TWO GOOVES
OF 3.2 WIDE AND 0.4 MM DEEP, IN GENERAL GOOVE WILL BE IN BASE METAL, IT
MAY DEVIATE IF SPECIALLY AGREED BY PURCHSER AND MAFR,
o MATCH DRILLING WITH MATTING FLANGES AND MATCH MARK FOR
IDENTIFICATION DURING ASSEMBLY.
o PWHT SHALL BE DONE WHEN REQUIRED BY RELEVAN FABRICATION SPEC.,

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 TUBE SHEET Tube sheet 2

CRITICAL DIMENSION TO CHECK :

C
R
THICKNESS
I
T HOLES PITCH
I
HOLE FINISH :
C
A SMOOTH FINISH
L
GOOD,BUT, LOW MECHANICAL STREANGTH BETWEEN TUBE
AND TUBE SHEET
GIVES GOOD TIGHTNESS
TO AVOIDS DAMAGE ON PIPE OD
ALLOWS EASY INSERTION OF PIPE

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 HE
Tube sheet 3
H - TUBE SHEET
E
A
T
ROUGH FINISH

GIVES MORE MECHANICAL STREANGTH BETWEEN TUBE AND

TUBE SHEET
BUT TUBE OD MAY GET LONGITUDINAL SCRATCHES WHICH
MAY LEAD TO LEAK PATH..
IN GENERAL :
LIGHT WALL TUBES NEED MORE SMOOTH FINISH
COMPARED TO HEAVY THICK TUBES.

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TUBE SHEET HOLES
TUBE SHEET HOLES

TOBE HOLES FOR EXPANDED TYPE JOINTS WILL HAVE GROOVES

IN GENERAL THERE WILL BE MINIMUM TWO GROOVES OF 3.2MM
WIDE AND 0.4 MM DEEP(FOR HYDROLIC EXPANSION TYPE GROOVE
SHALL BE 6.4 MM WIDE.
IF TUBE SHEET THICKNESS IS LESS THAN ONE INCH, ONE HOLE
MAY BE SUFFICIENT
NO GROOVES FOR SEAL WELD TYPE TUBE SHEET HOLES

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3 HE- BAFFLE Baffle 1

FUNCTION OF BAFFLE IN HE

IT DIRECT FLUID FLOW MOVEMENT

SUPPORT TUBES TO REDUCE FLOW INDUCED VIBRATIONS

TYPES

HORIZONTAL CUT PATTERN

VERCAL CUT PATTERN

Up & Down Flow pattern etc.,

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HE - BAFFLE
Baffle 2

CRITICAL ASPECTS TO CHECK

PATTERN
PITCH
STRAIGHTNESS
CLEARANCE BETWEEN SHELL ID AND BAFFLE OD.
TUBE TO HOLE CLEARANCE.
SPACING BETWEEN BAFFLES
DEBURRING
Bottom and Top Notch for Horizontal HEs for drain/vent.

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IMPINGEMENT BAFFLE
Impingplate

THISIMPINGEMENT BAFFLE LOCATED AT INLET OF NOZZLE

TO AVOID

1) SUSPENDED FLOW PARTICLES

2) TO REDUCE DIRECT IMPACT OF
FLOW FORCE ON TUBES

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SEALING STRIP
BY PASS SEAL STRIP

BY PASS SEALING STRIPS :

FUNCTION : TO SEAL THE BY PASS AREAS CAUSED BY BETWEEN

TUBE BUNDLE AND SHELL I.D

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 Tube to ts joint
HE TUBE TO T.S. JOINT

QUALIFICATION OF TUBE TO TUBE SHEET JOINT

EXPANSION JOINTS
EXPANSION AND WELDING MOCK UP TEST AS PER ASME SEC VIII DIV 1 APPEDIX A
TEMA SILENT ON THIS TESTS, TEST REQUIREMENT MAY BE BY AGREEMENT
BETWEEN PURCHASER AND MFGR or ASME SEC VIII DIV 1 APPEDIX A

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 Mock up test

- mock up block consists of minimum 9 tubes

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28
3 HEAT EXCHANGERS INTRODUCTION

TYPICAL JOINT DOUBLE TUBESHEET

Inner T/S
Shell Outer T/S

Channel
Shell

Tubes

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 3 HEAT EXCHANGERS INTRODUCTION

GENERAL DETAILS ABOUT THE JOB INCLUDING OVERALL DIMNS. :

HCL Hydrogenation Heater for Reliance Industries Limited ,Hazira
PROCESS FLUID:- SHELL SIDE - HCL / TUBE SIDE - STEAM*
U Tube Double Tube sheet HE.
DIMENSIONS :

Overall Length 6931 mm.

SHELL ID 440 mm x 12 Thk, TUBESHEET 476 OD
MATERIAL :
Shell / Dish end SA 516 Gr 70
Tube sheet SA 350 Gr LF2 46mm & 71mm ThK
U Tubes SA 334 Gr 6 19.05 OD x 2.77 mm thk

* SINCE THE PROCESS FLUID WAS STEAM, CUSTOMER

CONFIRMATION OF IBR WAS SOUGHT.

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4

TUBE SHEET DETAILS

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4 HEAT EXCHANGERS
TUBE SHEET DETAILS
TubeSheet - SA 350 Gr LF2. X 476 dia.
First T/s 46mm( inner) & second 71 mm ( outer).
Each T/s having two grooves of 3mm width and 0.4mm depth.
148 No of holes each of Dia. 19.25mm on 25.4mm traingular pitch.

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5

TUBE TO TUBE SHEET

JOINT

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5 HEAT EXCHANGERS
TUBE TO TUBE SHEET JOINT

Tube SA 334 Gr 6 Size 19.05mmx 2.77 mm Thk

Fully expanded joint.
8 to 10% expansion
% Thinning check and air test after expansion.

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6

TUBE SHEET TO TUBE SHEET

JOINT

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6 HEAT EXCHANGERS
TUBE SHEET TO TUBE SHEET JOINT

Full penetration joint with 25 mm gap in between the Tube sheets.

NDT as per drawing MPI
NDT suggested PT and UT in addition to MPI.

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7

REQUIREMENT OF MOCK UP

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7 HEAT EXCHANGERS
REQUIREMENT OF MOCK UP

WHY THE MOCK UP WAS REQUIRED TO BE DONE:

( TEMA DOESNT CALL FOR SUCH TESTS FOR U-TUBE EXCHANGERS)
To establish expansion parameters.

To check % thinning after expansion

To check axial load (pull out ) of tubes after expansion.

To check proper flow of tube material in the T/s grooves after

expansion.

To freeze the sequence of the expansion of the T/s to Tube joint.

SINCE TUBE SHEET ASSLY HAD DOUBLE EXPN. PORTION,

IT WAS ESSENTIAL TO DEMONSTRATE THE EXPANSION
ACHIEVED IN THE INNER TUBESHEET.

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8

MOCK UP TESTING

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8 HEAT EXCHANGERS
MOCK UP TESTING

DESCRIPTION OF THE MOCKUP:-

Tube sheets with same configuration as required in job.

17 No of holes used.

Pull out test carried out on Hole nos. 4,9&14 ,surrounded by at least two
rows.

Expansion in two stages.

% expansion checked in both Tube sheets with bore gauge.

ADDITIONAL TESTS DONE ON THE MOCKUP:

After satisfactory expansion, the joint with annular space was seal welded
first and then subjected to pneumatic test at 2.0 kg/cm2(g). pressure
followed by hydro test at 33.0 kg/cm2(g) and the results were leak tight.

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8.1 HEAT EXCHANGERS
DIM. REPORT OF MOCK UP

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8.2 HEAT EXCHANGERS
EXPN. RECORD OF MOCK UP

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8.3 HEAT EXCHANGERS
PULL OUT RECORD OF MOCK UP

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8.4 PULL OUT RECORD OF MOCK UP
HEAT EXCHANGERS
CONTD..

The pull out loads were found to be satisfactory when the tests were done :-

1. Required load - 56 kn actual 80 kn

2. Macro test was conducted after sectioning to confirm the proper flow of
tube material in the grooves after expansion, the flow of material was
satisfactory.

3. Hardness test were done on the inner expanded & unexpanded

surface of the tube and was with in 187 bhn.

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9

PROBLEMS INCURRED

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9.1 HEAT EXCHANGERS
PROBLEMS INCURRED

REQUIREMENT OF EXTRA LONG DIAL BORE GAGE FOR THE INNER

TUBESHEET:

In mock up stage , both ends of the tube sheets were accessible and hence
it was easy to check % expansion in both the tube sheets separately.

In actual job, only one end was accessible. So it required a long bore gauge
to check the expansion. Since the fabricator was not having the long bore
gauge,expansion of the outer T/s was checked and reported. The same was
referred to client for concurrence and was accepted by them based on
satisfactory mock up results.

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9.1 PROBLEMS INCURRED
HEAT EXCHANGERS
CONTD..

NDT SPECIFIED FOR THE EQPT WAS 100% RADIOGRAPHY :-

BV insisted the above requirement for the T/S TO T/Sheet weld joint

Due to the joint geometry, radiography could not be realised. UT was the
next suggested alternative. Again due to joint configuration /lesser width of
joint & limitation of scanning area only a small portion could be
examined leaving out the critical root penetration.

To counter this, special care for the root pass was undertaken by keeping
3 visible ports for examining the root penetration visually. The root
penetration was found satisfactory.

As per approved QAP only MP examination was specified for this joint
and hence accepted on this basis.

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9.2 HEAT EXCHANGERS
BV INSPECTION REPORT

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9.2 BV INSPECTION REPORT
HEAT EXCHANGERS CONTD..

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10

CUSTOMERS CONCURRENCE

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10 HEAT EXCHANGERS
CUSTOMERS CONCURRENCE

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11

CONCLUSION

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11 HEAT EXCHANGERS
CONCLUSION

TEMA does not give too much details about such type of Double T/s HE.

Maximum care was taken to do all possible testing and checks to

establish fool proof joint.

Still a better version of checks and testing may be possible.

Any additional information and experience on this topic is welcome.

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