Presentation on

HEAT EXCHANGER
 Heat Exchanger is a device to
transfer of heat from one medium to
other medium.

Two fluids of different temperatures, one flows through

the tubes and other flows out side tubes but inside the
shell.

Heat is transferred through the tube walls.

1. Tubular Exchanger
a. Shell and Tube Exchanger
b. U - Tube Exchanger
c. Kettle reboiler Type Exchanger
d. Double pipe Type Exchanger

2. Extended Surface
a. Plate type Exchangers
b. Finned Tube
1. Shell
2. Front End Head
3. Rear End Head
4. Inlet / Outlet Nozzles
5. Tube sheets
6. Tubes
7. Baffles
8. Tie Rods
9. Stiffener Plate
10. Impingement plate
 U- Tube
bundle

Kettle
re -boiler Type
Typical Example of Shell and
Tube

Double Pipe
Exchanger
1. Cross Flow to Tubes

2. Parallel Flow to Tubes

TEMA Tubular Exchangers Manufacturer's
Association
ASME Codes Sec-VIII-Div I and II
ASME Sec II A , B ,C ,D- Materials , Welding
consumables, properties
ASME Sec IX Welder qualification
ASME Sec V - NDT
ANSI standards
NACE standards/ recommended practices
API standards 660
Process Licensor's guidelines
 Shell
Front end Rear end
stationary head type head type

Alphabetical Letters given for the front end, shell and rear end
types.
Exchanger designated with three letter .

Example : AES, BES, AKT ... Etc,

 They support the tubes during assembly and
operation.
Help to prevent vibration from flow induced eddies.
Two types of baffles : 1. Plate type 2. Rod type

Baffle Cut : Cut in each baffle to permit the shell side

fluid to flow across the baffle .
Baffle cut can vary between 15% - 45 % of the shell ID
A triangular or rotated triangular
pattern will accommodate more
tubes than a square or rotated
square pattern.
A triangular pattern produce a
high heat-transfer coefficient.
Typical tube pitch of 1.25 times
the tube OD.
Mechanical cleaning of triangular
tubes pattern is very difficult.
Square pattern must be used
where mechanical cleaning is
TUBE PITCH : It is defined as the shortest distance
required.
between two adjacent tubes. Minimum tube pitch is
1.25 times of tube OD.
To join tubes and tubesheet and keep the
tubes structurally stable and support the
skeleton assembly under design conditions.
To prevent intermixing of shell and tube
sheet fluids.
To take care of Longitudinal, Compressive,
Mechanical and Thermal axial loads coming on
Expansion
tubes.
Tubes are attached to the tube sheet by
Pneumatic or hydraulic pressure or by roller
expansion.
Strength weld is one in which the design strength of
the weld is greater than or equal to the maximum
allowable axial tube strength.

Seal weld is used to supplement an

expanded tube joint to ensure tube joint
leak tightness.
Where the fluid velocity for the nozzle diameter is
high, an impingement plate is specified.
To distribute the fluid evenly to the tubes.
To prevent fluid enduced erosion, cavitations and
vibration
Shell : CS / SS / Non-ferrous
types
Tubes : CS / AS / SS / Non-
ferrous
Tube Sheet : Forgings / Plates
Nozzle Pipes : CS / AS / SS
Nozzles : CS / AS / SS
Gaskets : CAF, Spiral Wound, IJA,
Ring Joint type
Fasteners : CS / AS / SS
Name Plate : SS
Material Identification (Pressure parts)
Forming
Welding
Review of WPS / PQR / Welder Qualification
NDT
Stage and Final Inspections
Mock-up Assembly
Skeleton Assembly
Tube Bundle
Insertion of Tube Bundle into Shell
Testing (Hydro testing / Pneumatic testing)
Painting
Documentation
Packing / Protection / Dispatch
Provided to seal the joints against leak
Spiral wound with asbestos fill or graphite
fill
Metal jacketed
Ring joint type
Camprofile type
CAF only for less critical services
Material
SS 304, SS 316
Identify leak type and location:
hydrotesting
Attend leak :
gasket leak- re-tighten or replace
retubing or plugging leaky tubes
re-expansion of tube sheet joint/ re-welding
Cleaning of tube side /shell side as per
requirements
Install new bundles/ shell as per
requirement
Offer statutory tests as per schedule (IBR
Etc.)
Timely modifications in shell side/ tube side
as per CTS/CES/FDC/Licensor requirements
Civil jobs : foundation / pedestal/
structures
Inspection as received condition-
check for N2 purging of shell & tube
sides
Physical installation : Leveling
Site Checks: ITP format fill up
Alignment to upstream downstream
tube side / shell side piping
Insulation wherever necessary