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    Final HE IndustrialSeminar DeshbandhuRawat

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    The document describes the retubing of an ammonia condenser heat exchanger due to tube leakage and failure. 22 of the 4478 tubes in the shell and tube heat exchanger were punctured, ruptured or rusted and needed to be replaced. The condenser reduces the temperature of ammonia gas from 60°C to 40°C and is a critical component in the ammonia system. The document provides details on the specifications, design, maintenance procedures and testing done during the retubing process to repair the leaking tubes.

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    Final HE IndustrialSeminar DeshbandhuRawat

    Uploaded by

    deshbandhu_rawat_me12
    55 views22 pages
    The document describes the retubing of an ammonia condenser heat exchanger due to tube leakage and failure. 22 of the 4478 tubes in the shell and tube heat exchanger were punctured, ruptured or rusted and needed to be replaced. The condenser reduces the temperature of ammonia gas from 60°C to 40°C and is a critical component in the ammonia system. The document provides details on the specifications, design, maintenance procedures and testing done during the retubing process to repair the leaking tubes.

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    The document describes the retubing of an ammonia condenser heat exchanger due to tube leakage and failure. 22 of the 4478 tubes in the shell and tube heat exchanger were punctured, ruptured or rusted and needed to be replaced. The condenser reduces the temperature of ammonia gas from 60°C to 40°C and is a critical component in the ammonia system. The document provides details on the specifications, design, maintenance procedures and testing done during the retubing process to repair the leaking tubes.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    55 views22 pages

    Final HE IndustrialSeminar DeshbandhuRawat

    Uploaded by

    deshbandhu_rawat_me12
    The document describes the retubing of an ammonia condenser heat exchanger due to tube leakage and failure. 22 of the 4478 tubes in the shell and tube heat exchanger were punctured, ruptured or rusted and needed to be replaced. The condenser reduces the temperature of ammonia gas from 60°C to 40°C and is a critical component in the ammonia system. The document provides details on the specifications, design, maintenance procedures and testing done during the retubing process to repair the leaking tubes.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 22

    Submitted by: Deshbandhu Rawat (0715040017) 4th Year Mechanical

    RETUBING OF AMMONIA CONDENSER (E-510)


    A CRITICAL HEAT ECHANGER IN AMMONIA DEPT. 20 TPH AMMONIA HANDLED REDUCES TEMPERATURE OF AMMONIA GAS FORM 60OC to 40OC

    PROBLEM DETECTION
    A leakage of Ammonia Gas was detected in the Ammonia

    Condenser (R-510) Major Problem was confirmed and was decided to Investigate and Repair. When checked 22 of the 4478 tubes fitted were either punture, raptured or rusted during its usage.

    Shell & Tube type

    SIMPLE SHELL & TUBE TYPE DESIGNED MODEL

    SHELL & TUBE TYPE


    Bonnet Tubesheet Shell Spacers & Tierods Tubes Baffles Shell Nozzle Channel Channel Flange

    Channel

    Shell Nozzle

    Saddles

    Drain Plug

    Shell Nozzle

    FIXED TUBE-SHEET H.E. 1. Simple construction, Low cost, Robust 2. Differential expansion not possible 3. Outside of tubes cannot be cleaned

    TYPICAL SHELL-TUBE HE WITH NOMENCLATURE

    Pass Partition

    DESIGN PRESSURE & TEMPERATURE


    Working Fluids

    Shell Side: Liquid Water


    Safe Working Pressure

    Tube Side: Ammonia Gas

    Shell Side: 25 kg/cm2


    Tested Working Pressure

    Tube Side: 6 kg/cm2

    Shell Side: 37.5 kg/cm2


    Working Temperatures

    Tube Side: 9 kg/cm2

    Shell Side: -20O to 180O C

    Tube Side: 60OC to 40OC

    CONDENSER SPECIFICATIONS
    Design Vendor

    : Snamprogetti, Italy Make : L & T Powai Pressure Vessel Type : Two Pass, Shell & Tube H.E. With Fixed Tubesheet Inside Diameter : 2705 Mm Length Of Vessel : 25000 Mm MOC Of Shell Plates : SA 387 Gr. 22 Class-2 Corrosion Allowance : 1 Mm

    CONTINUED
    Joint Efficiency
    PWHT Insulation Weight Flooded Weight Weight Of Internals

    : 100% : Required :160 Mm Thick : 265000 Kg (Approx.) : 398000 Kg (Approx.) : 319471kg (Approx.) : 584471 Kg (Approx.)

    (Including Catalyst) Operating Weight

    HEAT EXCHANGE ACTION INSIDE TUBES

    TEMPERATURE PROFILE- PARALLEL FLOW

    TEMPERATURE PROFILE- COUNTER FLOW

    DIFFERENT CONFIGURATIONS OF TUBES:


    Tubes may be Straight tubes or U bend tubes. Tubes fixed at the ends to Tube-sheets to form Tube-bundles.

    Fixing is done either by expanding the tubes in to tube-sheet (called

    Tube Rolling) or by expansion & welding. Standard tube patterns are:


    Circular

    Triangular
    Square Triangular pattern (Results in compact design)

    If shell side requires mechanical cleaning (as in case of a dirty

    fluid), Triangular pattern cannot be used. Pitch- Min. center to center distance between adjacent tubes. Usually at minimum pitches of 1.25 times the tube OD.

    FOULING

    Deposition of unwanted material on a heat transfer surface.

    Fouling the major unresolved problem in heat transfer since 1972 and still same in 2006. Increased capital cost due to larger equipment Additional energy required due to (a) increased pumping (b) reduction in energy recovered Maintenance costs for chemical treatment and cleaning Loss of throughput material Downtime costs

    FOULED TUBE BUNDLE

    FOULED BUNDLE CLEANING

    BEFORE

    AFTER

    Fluid velocity high velocity minimizes all modes but requires more pumping power

    Wall temperature affects scaling , biofouling, chemical reaction rates


    Nature of fluid

    Tube material

    Related Terms in Exchangers Maintenance:


    1. Depressurization / Pressurization 2. Isolation of Exchanger 3. Taper Plugs 4. Soap Solution Test 5. Leaky tubes 6. DPT

    7. Thickness Measurement
    8. Helium Test / Hydro Test / Pneumatic Test

    SOAP SOLUTION TEST

    DIE PENETRANT TEST (DPT)

    MAINTENANCE DUE TO LEAKAGE:


    1. Open the both side end covers of exchanger 2. Cleaning of tubes with Hydro-jet and Nylon brush 3. Leakage Testing of exchangers 4. Plugging out of leaky tubes 5. Replacement & Welding of new tubes

    THANK YOU

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