ASIAN BUSINESS CONSULTANTS.

PUNE. INDIA .
 TOPICS
INTRODUCTION
BASIC CONSTRUCTION
TYPES &
NOMENCLATURE
BASIC DESIGN RULES
DETAILS OF VARIOUS
PARTS
PROBLEMS/TROUBLE
SHOOTING
MAINTENANCE/
INSPECTION
CASE STUDIES
 Introduction
Heat Exchanger is mechanical equipment
in which heat is exchanged between two
fluids.

 Heat exchange equipment is vital to the

operation of the Process plant. Its purpose
is to ensure effective heat transfer as per
design, functional requirements – resulting in
LARGE HEAT/UTILITY SAVINGS UN-INTERRUPTED OPERATION
PREVENT UNSCHEDULED OUTAGES
SAFETY, RELIABILITY
Types of heat exchanger

Based on service
Based on construction
Types of Exchangers Based on Service
Exchanger:
It is a unit that exchanges heat between two process streams without
phase change; i.e. liquids are not evaporated nor condensed.

Cooler:
Cools the process fluids without phase change.

Condenser:
Condenses process vapor stream.

Re-boiler:
Provides latent heat of vaporization to bottom of distillation/
fractionation column.

Pre-heater:
Uses steam or hot process stream to heat & or vaporize the feed to
processing unit.
Types of Exchangers Based on Construction

Tubular heat exchanger:

U tube type heat exchanger
Fixed tubesheet heat exchanger
Floating head type heat exchanger
Hair pin type
Pipe in pipe heat exchanger
Fin fan type exchanger
Plate type heat exchanger
Spiral plate type heat exchanger
SHELL AND TUBE HEAT
EXCHANGERS
Why shell-and-tube?
Scope of shell-and-tube
Construction
TEMA standards
Choice of TEMA type
Fluid allocation
Design problems
Enhancement
Improved designs
 Why shell-and-tube?
S&T accounted for 85% of exchangers supplied
to oil-refining, chemical, petrochemical and
power companies.
Why?
Can be designed for almost any duty with a very wide
range of temperatures and pressures
Can be built in many materials
Many suppliers
Repair can be by non-specialists
Design methods and mechanical codes have been
established from many years of experience
 Functions of S&T exchangers
Heating (gas or liquid)
Cooling without condensing (gas or liquid)
Condensing of vapors (partial condensing OR full
condensing)
Evaporating liquid (partial or full)
Based on the above S&T exchangers are known
as:
Heaters / Coolers / Boilers
Condensors / Trim coolers /Trim condensors
Vaporisers / Reboilers
 Designation of S & T exch

TEMA - R C B –fundamental std

Class ‘R’ – Used for severe requirement of
Petroleum and related processing applications.
Class ‘C’ – Used for moderate requirements of
commercial and process applications.
Class ‘B’ – Used for chemical process service.

STATIONARY HEAD TYPES (A, B, C, D)

SHELL TYPES (E, F, G, H, J, K)
REAR HEAD TYPES (L, M, N, P, S, T, U)
 Scope of shell-and-tube
Maximum pressure
– Shell 300 bar (4500 psia)
– Tube 1400 bar (20000 psia)
Temperature range
– Maximum 600oC (1100oF) or even 650oC
– Minimum -100oC (-150oF)
Fluids
– Subject to materials
– Available in a wide range of materials
Size per unit 100 - 10000 ft2 (10 - 1000 m2)
Can be extended with special
designs/materials
 Constructional details
Shell side: Shell, Shell covers, shell
nozzles

Tube side: Tube sheet, Tubes, Baffles, Tie

rods, Spacers, Impingement
plate, Channel shell, Channel
cover, Tube side nozzles
Non-pressure
attachments: Saddles, structural
Associated piping for shell side and tube side
 Construction
Bundle of tubes in large cylindrical shell
Baffles used both to support the tubes and to
direct into multiple cross flow
Gaps or clearances must be left between the
baffle and the shell and between the tubes
and the baffle to enable assembly
Shell

Tubes
Baffle
Shell-side flow
Shell and tube HX parts
Shell
Tubes
Shell cover
Channel box
Channel cover
Tube sheet
Floating head
Baffles
Tie rods
 Major Parts of shell & tube heat exchanger
Shellside
Flow In Nozzle
Tubeside
Flow Out
Shell
Channel

Baffles
Tube Bundle

Tube Sheet
Shellside
Flow Out
Tubeside
Flow In
Exch. Major Parts & Generally used MOC
Shell:
Carbon steel (CS), Stainless steel (SS), Titanium, Carbon steel
cladded with SS, Titanium or Monel
Channel:
Generally similar to tube MOC.
Carbon steel (CS) , Stainless steel (SS), Titanium, Carbon steel
cladded with SS, Titanium or Monel
Tube sheet:
Carbon steel (CS), Stainless steel (SS), Titanium , Carbon steel
cladded with SS, Titanium or Monel
Tubes:
Carbon steel (CS), Stainless steel (SS), Admiralty Brass, Titanium
(Ti) , Monel
Tubes are available in different diameters.
Commonly used OD:
3/8" - 9.5 mm 5/8” – 16 mm, ¾” - 19.05 mm, 1” – 25.4 mm,
2” – 50.8 mm
Exch. Major Parts & Generally used MOC
Gasket:
CAF (Asbestos), Iron jacketed gasket with Asbestos
Spiral wound gasket (SS, Monel, Titanium filled with PTFE, Grafoil,
Asbestos)
Solid flat metal : Soft Iron, Aluminum, Copper, Brass, Monel, SS
O rings,
Baffles:
Types of baffles:
Segmental baffle , Strip baffle, Disc and doughnut baffle, Orifice
baffle , Longitudinal baffle
Tie Rods & Spacer Tubes:
MOC of baffles, tie rods, spacer tubes are similar to tube MOC or
shell MOC.
Tube Pattern, Pitch: Triangular, Square

Tube to tubesheet Joints: Welded with light expansion,

Expanded, expanded with seal welded.
Selection Of Heat Exchanger
It must meet the process requirements
It must withstand the service condition
It must be maintainable
Exchanger Cost
Capital cost of installation
Area occupied by the equipment
Availability and cost of water
Pressure drop
Significance of Different Types of Heat Exch.
Fixed Tube sheet Exchanger:
Both tubesheet fixed to shell.

Application Best Suited:

For cleaner fluid on shell side
Low cost

Limitations:
Temp. difference on shell side & tube side should be
less than 93 deg c.
Fixed Tube sheet Design
 Fixed Tubesheet type Heat Exchanger
Front End
Rear End
Stationary Head Shell Type
Head Type
Type
A E M

Channel and Fixed Tubesheet

One Pass Shell
Removable Cover Stationary Head
Significance of Different Types of Heat Exch.
Floating Head Type:
One tubesheet floats in shell and bundle may be
removable from shell, back cover can be removed to
expose tube ends.
Application Best Suited:
High temperature difference on shell & tube side
Cleaning possible with floating end cover

Limitations:
Internal gasket offer danger of leakage
Only horizontal units
Typical floating head exch
Significance of Different Types of Heat Exch.
U Tube:
Only one tube sheet required, tube bends in U
shape, Bundle is removable

Application Best Suited:

High temperature difference on shell & tube side
Clean service on tube side

Limitations:
Higher tube side velocities can cause erosion on tube
ends
Fouling / subsequent cleaning problem
Typical U tube exch
 U Tube type Heat Exchanger
Front End
Rear End
Stationary Head Shell Type
Head Type
Type
C E U

Channel Integral
with Tube sheet and One Pass Shell U-Tube Bundle
Removable Cover
U Tube type Heat Exchanger
Significance of Different Types of Heat Exch.
Hair Pin Type Exchanger:
Extended surface due to longitudinal finning. Tube
bundle can be removed from shell for cleaning.

Application Best Suited:

Smaller transfer area required
Suitable for higher pressure requirement
Low space

Limitations:
Smaller capacity
 Hair Pin type Heat Exchanger
Shell Cover Gasket External Fin Pipe
Vent Shell

Shell
Cover

Return Bend
(welded)

Drain Sliding Fixed

Support Support

Twin Flange Shell End Piece

Double Pipe Exchanger
Typical Kettle reboiler
Helical exchangers

Less fouling on
shell side
High heat
transfer
High capital cost
and maintenance
cost
 Applicable Codes & Standards
ASME SEC VIII Rules for Construction of
DIV 1/2 Pressure Vessels

TEMA Standards of the Tubular

Exchanger Manufacturer's
Association

API 660 Shell and Tube Heat

Exchangers for General
Refinery Services

API 661 Air-Cooled Heat Exchangers

for General Refinery Service
 TEMA Classifications
TEMA Class Application Example
________________________________________________________________________________________________________________________________

R Severe environments Refineries

C Moderate service Building

services,
commercial,
and general
process
industries

B Chemical process Chemical

manufacturing
 TEMA standards
The design and construction is usually based on TEMA
8th Edition 1998
Supplements pressure vessel codes like ASME and BS
5500
Sets out constructional details, recommended tube
sizes, allowable clearances, terminology etc.
Provides basis for contracts
Tends to be followed rigidly even when not strictly
necessary
Many users have their own additions to the standard
which suppliers must follow
 TEMA Designation System Example

TEMA Size and Type Normally Written: 23–192 AES

Straight Tube
Length 192”
23”
(16’ – 0”)
Shell
I.D.

Type “A” Channel

Type “E” Shell Type “S” Split-Ring
Single-Pass Floating Head
 TEMA terminology

Rear
Front end Shell end
stationary head head
type type

Letters given for the front end, shell and rear end
types
Exchanger given three letter designation
Above is AEL
 Front head type
A-type is standard for dirty tube side
B-type for clean tube side duties. Use if possible
since cheap and simple.

A B

Channel and removable cover Bonnet (integral cover)

 More front-end head types
C-type with removable shell for hazardous tube-side
fluids, heavy bundles or services that need frequent
shell-side cleaning
N-type for fixed for hazardous fluids on shell side
D-type or welded to tube sheet bonnet for high
pressure (over 150 bar)

B N D
 Shell type
E-type shell should be used if possible but
F shell gives pure counter-current flow with two
tube passes (avoids very long exchangers)
Longitudinal baffle
E F

One-pass shell
Two-pass
shell
Note, longitudinal baffles are difficult to seal with
the shell especially when reinserting the shell after
maintenance
 More shell types
G and H shells normally only used for horizontal
thermosyphon reboilers
J and X shells if allowable pressure drop can not be
achieved in an E shell

G H
Longitudinal
Split flow baffles Double split flow

J X

Divided flow Cross flow

 Rear head type
These fall into three general types
fixed tube sheet (L, M, N)
U-tube
floating head (P, S, T, W)
Use fixed tube sheet if T below 50oC,
otherwise use other types to allow for
differential thermal expansion
You can use bellows in shell to allow for
expansion but these are special items which
have pressure limitations (max. 35 bar)
 Fixed rear head types
L

Fixed tube sheet

L is a mirror of the A front end head

M is a mirror of the bonnet (B) front end
N is the mirror of the N front end
 Floating heads and U tube
Allow bundle removal and mechanical cleaning
on the shell side
U tube is simple design but it is difficult to clean
the tube side round the bend
 Floating heads
T S

Pull through floating head Similar to T but with smaller shell/

Note large shell/bundle gap bundle gap

Split backing ring

 Other floating heads
Not used often and then with small exchangers

P W

Outside packing to give Externally sealed floating tube sheet

smaller shell/bundle gap maximum of 2 tube passes
TEMA Types
 Design Practices
Comparable heat transfer coefficents on shell and
tube sides.
Hot fluid in tubes
Viscous fluid in shell side
Dirty fluid in tubes
Counterflow preferred
Triangular pitches are preferred
Velocities >1m/s , <2m/s
Baffle spacing < 1m or shell dia whichever is the
lower.
 DESIGN STEPS

Thermal (process) design

Mechanical design
 Data for process design
Operating fluids: their properties (chemical,
physical and thermal properties)
Operating conditions: Inlet / outlet
temperature/flow/pressure
Heat duty : Heat transfer requirement
Heat transfer co-efficients
Fouling factors
Basic equation for thermal design is
Q = U A F (LMTD)
 Process design steps

Select a basic type

Select tentative set of modify design

design parameters parameters

Rating of design
thermal perf/pressure not OK
drop calculations

evaluation of design ok go to mechanical

Q, delta P accept? design
Modes of Heat Transfer
Conduction
Convection
Radiation
Fourier's law for Heat conduction

Q = -k A (dT/dx)

Q = heat duty, BTU/hr

k = thermal conductivity of the material, BTU/hr-ft 2 - o F/ft
A = Area perpendicular to the heat flow, ft2
dT/dx = temperature gradient in direction of heat flux, ºR/ft
Thermal conductivities of material are determined experimentally or can be estimated
using empirical methods when experimental data is not available, as is generally the
case with liquid and gas mixtures.
Equation for Convection

Heat transfer by convection can be described by an equation

similar to the equation for conduction.
Q = h A T
where
Q = heat duty, BTU/hr
h = heat transfer coefficient due to convection, BTU/hr-ft 2 - oF
A = surface area, ft 2
DT = temperature difference between the surface and the bulk fluid, oF

The heat transfer coefficient due to convection depends on the properties of the fluid,
geometry of the surface and flow rate. It can be determined experimentally or, given
the amount of data available, be calculated by using the dimensionless groups; Nusselt,
Prandtl, Reynolds, and Grashof numbers.
Stefan - Boltzmann law: Energy emission by radiation

Q = s e AT 4

Q = emitted energy, BTU/hr.

s = radiation coefficient for a black body, BTU/ft. 2 -hr.- o R 4
e = emissivity, dimensionless
A = surface area of emitting body, ft.2
T = surface temperature of emitting body, oR

e= ranges from 1.0 for a black body to 0.02-0.04 for polished metal surfaces.
Shell & Tube Heat Exchangers

•Floating Head Design

•U-tube Design

•Fixed Tube Sheet Design

•Kettle Design

Heat transfer involving unfired shell and tube heat

exchangers or air fins is mainly concerned with
convection as the mechanism.
Shell and Tube Exchanger

2 pass tube, 1 pass shell

Shell side Tube side
Baffles inlet outlet
Shell

Partition plate

Bonnet/Dome Shell side

Tubes Tube side
outlet Tube sheet inlet

By Bj 59
Baffle Designs
Thermal Design

•Heat duty
Quantity of heat to be transferred from hot stream to
cold stream

•Area required for heat exchange

Surface area of tubes required for transferring the
heat duty

By Bj 61
Calculation of heat duty

Q = m Cp T

Q Heat duty (Joules/hr)

m Mass flow rate (Kg/hr)
Cp Specific heat (Joules/Kg deg C)
T Temperature difference between inlet and outlet

By Bj 62
Area required for heat transfer

A = Q
(U* Tln)

Q Heat duty (Joules/hour)

U Overall Heat transfer coefficient (Joules/m2 hr deg C)
Tln Log mean Temperature difference (deg C)
A Area required for heat transfer (m2)

By Bj 63
Heat transfer coefficients - Typical
 Heat transfer coefficients - Typical

Units- BTU/hr ft2 deg F

Log Mean Temperature Difference (LMTD)
T1 t2

T2 T1 = T1-t2 t1
T2 = T2-t1

Tln = (T1 - T2)/ ln(T1/ T2 )

By Bj 66
Fouling And Scaling

Fouling refers to any change in the solid boundary separating two

heat transfer fluids, whether by dirt accumulation or other means,
which results in a decrease in the rate of heat transfer occurring
across that boundary. Fouling may be classified as

1. Corrosion fouling.
2. Biofouling.
3. Particulate fouling.
4. Chemical reaction fouling
5. Precipitation fouling (ex.—Scaling).
1. Corrosion fouling.
The heat transfer surface reacts chemically with elements of
the fluid stream producing a less conductive, corrosion layer on
all or part of the surface.

2. Biofouling.
Organisms present in the fluid stream are
attracted to the warm heat-transfer surface where they attach, grow,
and reproduce. The two subgroups are microbiofoulants such as slime
and algae and macrobiofoulants such as snails and barnacles.

3. Particulate fouling.
Particles held in suspension in the flow stream will deposit
out on the heat-transfer surface in areas of sufficiently
lower velocity.
4. Chemical reaction fouling
(ex.—Coking). Chemical reaction of the fluid takes place
on the heat-transfer surface producing an adhering solid product
of reaction.
5. Precipitation fouling
(ex.—Scaling)A fluid containing some dissolved material
becomes supersaturated with respect to this mate- by using,
in concert with adequate velocities, some form of extended
surface.
Velocity in Cooling Water tubes

•Velocity of 1 to 2 m/s is considered ideal.

•Higher velocities increase erosion.
•Lower velocities increase deposition of salts and results in
scale formation.
•Scale formation reduces heat transfer.

By Bj 70
Calculation of Velocity of Cooling water velocity in
tubes

•Using Ultra sonic flow meter.

•Equipments required- Ultrasonic flow meter
•Data required Hx Dimensions
•By heat balance
•Equipments required- Thermometer
•Data required Hx Dimensions,Shell side flow,inlet and
outlet temperatures

By Bj 71
 Monitoring of Heat Exchanger for fouling

Equation used
A = Q
(U* Tln)

Data required
•Hx Dimensions.
•Inlet and outlet temperatures.
•Operating Heat duty
U (Overall heat transfer coefficient) is calculated and monitored

By Bj 72
 Thermal design - DATA
Example 7.3
Kerosene (shell) / Crude oil (tube) HX ref DQ kern Page 151

Data In Shell or tube

Hot fluid Kerosene S (Enter S if in shell) (Enter T if in tube)
Cold fluid Crude oil T (Enter S if in shell) (Enter T if in tube)
Shell side data
Kerosene inlet temp 390 deg F
Kerosene outlet 200 deg F
Kerosene flow 43800 lbs/hr
Kerosene density 0.73 gm/cc 45.57 lb/ft3
Kerosene Cp 0.605 BTU/lb deg F
Kerosene ka 0.0765 BTU/hr sqft deg F/ft
Kerosene viscosity 0.97 cP 2.328 lb/hr ft
Kerosene fouling factor 0.001 1/BTU/hr sq ft deg F
Tube side data
Crude oil inlet temp 100 deg f
Crude oil outlet 170 deg f
Crude oil density 62.43 lb/ft3 1 gm/cc
Crude oil Cp 1 BTU/lb deg F
Crude oil ka 0.348 BTU/hr sqft deg F/ft
Crude oil viscosity 1 cP 2.4 lb/hr ft
Crude oil viscosity at wall temp 1 cP 2.4 lb/hr ft
Crude oil fouling factor 0.002 1/BTU/hr sq ft deg F
Thermal design - Calculations

Calculations
Heat duty 5034810 BTU/hr
Assume U 75 BTU/hr sqft deg F
Flow Path C (Enter C for counter flow , P for parallel)
LMTD 152.20 deg F
Initial Area estimate 441.08 sq ft
Heat Transfer Coefficient tube side

Heat transfer coefficient tube side

Assume Tube dimensions
outside dia 1 inch 0.083 ft
Tube length 8 feet
tube thickness 0.083 inch
Inside dia 0.834 inch 0.070 ft
Tube sheet allowance 6 inch
net tube length available 7.5 feet
No of tubes 224.64 tubes say 225.00
Tube velocity
Tube side flow rate 71925.8571 lbs/hr
Assume no of tubes 44 should be > 225.00
Assume no of tube passes 4 passes
no of tubes per pass 11 tubes/pass
Tube velocity 7.67 ft/sec
Mass flow rate in tube 1723585.65 lb/hr sq ft
Reynolds number 49912
Prandtl number 6.90
Heat transfer coeff tube side 1475.94 BTU/hr sqft deg f
hio 1230.93 BTU/hr sqft deg f
Heat Transfer Coefficient shell side

Film coefficent Shell side

Assume Tube pitch 1.25 inch
Pitch type T (Enter T for Triangular and S for square)
Assume shell ID 12 inch 1 ft
Clearance between tubes 0.25 inch
Assume baffle spacing 5.5 inch
Cross flow area 0.092 sq ft
shell side Mass flow rate 477818.18 lb/hr sq ft
Shell side Eq tube dia 0.71 inch 0.06 ft
Reynolds number 12159.52
Prandtl number 18.41
heat transfer coeff shell side 216.63 BTU/hr sqft deg f
Heat Transfer Coefficient Overall

Overall heat transfer coeffcient

U 113.29 BTU/hr sqft deg f
Area required 291.99 sq ft
Area assumed 92.15 sq ft
 Applicable design
codes/standards/practices
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
Process Licensor's guidelines
 TEMA guidelines
Not to exceed Inside Diameters of 100 inches (2450
mm)
Product of Nominal Dia (inches) and Design
Pressure (psi) not to exceed 1,00,000 (17.5 x 106 kpa)
Not to exceed Design Pressure of 3000 psi (2068
kpa)
INTENT OF THESE PARAMETERS IS TO LIMIT THE
MAXIMUM WALL THICKNESS TO APPROXIMATELY
3 inches (76 mm) AND MAXIMUM STUD DIAMETER
TO 4 inches (102 mm)
 Materials used for S&T
exch:
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
 Allocation of fluids
Put dirty stream on the tube side - easier to clean
inside the tubes
Put high pressure stream in the tubes to avoid thick,
expensive shell
When special materials required for one stream, put
that one in the tubes to avoid expensive shell
Cross flow gives higher coefficients than in plane
tubes, hence put fluid with lowest coefficient on the
shell side
If no obvious benefit, try streams both ways and see
which gives best design
 Allocation-shell & tube side
fluids
Fouling : Depends of type of fluid, extent
of fouling, facilitate cleaning
Flow rate: lower flow in tubes
Corrosion: more corrosive in tubes
Viscosity : high viscosity in shell
Pressure : high pressure in tubes
Temp: high temp in tubes (MoC)
HT coefficient: lower HTC fluid in shell
 Which type ? - + and -

Parameter Fixed TS U tube FL head

Bundle removal No Yes Yes

Provision for expansion No Yes Yes
Tube inside cleaning Yes Difficult Yes
Tube outside cleaning No Yes Yes
Cost Low Low High
 Selection of shell types
E type shell ( single General duties
pass)
K type shell Shell side fluid
boiling/phase separation
F type shell For more passes of shell
side
G or H type shell Thermosyphon type
reboilers
J or X type shell When shell side pressure
drop is restricting
 Selection of tube side types
B type front head Front end stationary head

A type front head When frequent cleaning of

tube side is required
M type rear head Fixed tubesheet type
L type rear head With A type and odd No. of
tube passes
K type rear head Kettle type exchangers
S type rear head Floating head type
Shell-to-bundle clearance (on diameter)
150
T

100
Clearance, mm

P and S

50

0 Fixed and U-tube

0 0.5 1. 1.5 2.0 2.5
0 diameter, m
Shell
 Shell thickness
t
Ds p p
t
p is the guage pressure in the shell
t is the shell wall thickness
 is the stress in the shell
From a force balance
pDs
2t  pDs hence t
2
 Typical maximum exchanger sizes

Floating Head Fixed head & U tube

Diameter 60 in (1524 mm) 80 in (2000 mm)

Length 30 ft (9 m) 40 ft (12 m)
Area 13 650 ft2 (1270 m2) 46 400 ft2 (4310 m2)

Note that, to remove bundle, you need to allow at least

as much length as the length of the bundle
 Example
BES
Bonnet front end, single shell pass and split
backing ring floating head
 Example 1
Debutaniser overhead condenser

Hot side Cold side

Fluid Light hydrocarbon Cooling water

Corrosive No No
Pressure(bar) 4.9 5.0
Temp. In/Out (oC) 46 / 42 20 / 30
Vap. fract. In/Out 1/0 0/0
Fouling res. (m2K/W) 0.00009 0.00018
 Example 2
Crude tank outlet heater

Cold side Hot side

Fluid Crude oil Steam

Corrosive No No
Pressure(bar) 2.0 10
Temp. In/Out (oC) 10 / 75 180 / 180
Vap. fract. In/Out 0/0 1/0
Fouling res. (m2K/W) 0.0005 0.0001
What is this?
 Shell-side enhancement
Usually done with integral, low-fin tubes
– 11 to 40 fpi (fins per inch). High end for
condensation
– fin heights 0.8 to 1.5 mm
Designed with o.d. (over the fin) to fit into the
a standard shell-and-tube
The enhancement for single phase arises
from the extra surface area (50 to 250% extra
area)
Special surfaces have been developed for
boiling and condensation
 Low-finned Tubes
Flat end to go into tube sheet and
intermediate flat portions for baffle locations

Available in variety of metals including

stainless steel, titanium and inconels
Tube-side enhancement using inserts

Spiral wound wire and twisted tape

Increase tube side heat transfer coefficient but at
the cost of larger pressure drop (although
exchanger can be reconfigured to allow for
higher pressure drop)
In some circumstances, they can significantly
reduce fouling. In others they may make things
worse
Can be retrofitted

Twisted tape
Wire-wound inserts (HiTRAN)
Both mixes the core (radial mixing) and
breaks up the boundary layer
Available in range of wire densities for
different duties
 Baffles
Provided for bundle stiffness
Direct flow – Heat transfer
Types
Plate baffles
Rod baffles
Helical baffles
Conventional Shell-side Flow
 Shell-side axial flow
Some problems can be overcome by having axial flow
Good heat transfer per unit pressure drop but
– for a given duty may get very long thin units
– problems in supporting the tube
ROD baffles (Phillips petroleum)
introduced to avoid vibrations by providing additional
support for the tubes
also found other advantages
– low pressure drop
– low fouling and easy to clean
– high thermal effectiveness
 ROD baffles
Tend to be about 10% more expensive for the
same shell diameter
Twisted tube (Brown Fin tube)
Tubes support each other
Used for single phase and condensing duties in
the power, chemical and pulp and paper
industries
Shell-side helical flow (ABB Lummus)
Independently developed by two groups in
Norway and Czech Republic
 Comparison of shell side
geometries
Twisted Segmental Helical ROD
tube baffles baffles baffles
Good p Y N Y Y
High shell N Y Y N
Low fouling Y N Y Y
Easy Y With square With square Y
cleaning pitch pitch
Tube-side Included With inserts With inserts With inserts
enhance.
Can give Y N N Y
high 
Low Y With special With double Y
vibration designs helix
 Tube types

Straight tube and U tube

Spiral tubes
Finned tubes: enhanced heat transfer
Circumferentially finned/Longitudinally finned
Helically finned
 Tube layouts

pitch
Triangular Rotated Rotated
Square square
30o triangular
90o 45o
60o

Typically, 1 in tubes on a 1.25 in pitch or 0.75 in tubes on

a 1 in pitch
Triangular layouts give more tubes in a given shell
Square layouts give cleaning lanes with close pitch
Tube layout pattern and pitch
 Purpose of Tube to
Tubesheet joint
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 tubes.
 Types of tube-tubesheet joint
Expanded joint
Expanded tube joint is the tube
to tube sheet joint achieved by
mechanical or explosive
expansion of the tube into the
tube hole in the tubesheet.
Types of tube-tubesheet joint

Strength weld is one in which the design strength of

the weld is greater than or equal to the maximum
allowable axial tube strength. A strength weld shall
be designed to transfer all of the longitudinal,
mechanical and thermal axial loads in either
direction from the tube to the tubesheet as well as
provide tube joint leak tightness.
Types of tube-tubesheet joint
Seal weld is used to supplement an expanded tube
joint to ensure tube joint leak tightness.
Recommended to use for following cases where
1. intermixing of shell and tube side fluid causes safety hazards.
2. Lethal fluids are used.
3. Hydrogen service with partial pressure greater than 6.8 bar
 Tube to tube sheet joint
parameters
Tube MoC, hardness
Tube sheet MoC, hardness
Groove shape
Cleanliness of tube and tubesheet
Type of expander, torque values
Amount of expansion
4-5% for SS
7-8% for CS
10-12% for old tubes re-used
 How thermal stresses are
taken care of?
By properly selecting the type of exchanger
For e.g., fixed tubesheet exch: max delta T shall
be 38 deg C as thumb rule.
Expansion joint on shell can take care thermal
expansion
 How thermal stresses are
taken care of?
Provision of internal
bellows on one pass
tube – vertical exch:

U tube design

Floating head design

 Gaskets
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
Problems of Conventional S & T
Zigzag path on shell side leads to
Poor use of shell-side pressure drop
Possible vibration from cross flow
Dead spots
– Poor heat transfer
– Allows fouling
Recirculation zones
– Poor thermal effectiveness, 
Problems encountered in
HX operation
Poor heat transfer
Plugged tubes due to fouling
Low velocities
High coolant temperatures
Air pockets in HX
Tube leaks
Corrosion , erosion
Sudden extra expansion
High pressure drops
Fouling of tubes/shell side with deposits
 Problems in S&T Exch
Fouling - shell side or tube side

Leaks – Tube leak/Gasket leak/ roll leak

Corrosion /Erosion - Tube side/ shell side

Vibration /Stress related problems

Inherent design deficiencies

 What is fouling?
Fouling is any kind of deposit on HT surface that
reduces heat transfer. Fouling is indicated by
Higher pressure drop
Lower heat duty
Fouling can be due to

Sedimentation: Cooling water deposits

Process generated: polymerization/coking
Corrosion products: oxide (rust) scales
Microbiological fouling: bacterial action
Design discrepancies
 Fouling
Shell and tubes can handle fouling but it can be reduced
by
keeping velocities sufficiently high to avoid deposits
avoiding stagnant regions where dirt will collect
avoiding hot spots where coking or scaling might
occur
avoiding cold spots where liquids might freeze or
where corrosive products may condense for gases

High fouling resistances are a self-fulfilling

prophecy
 Factors affecting fouling
Velocity- flow- lower velocity, higher fouling
Chemical reaction products
Corrosion products
Temperature
Bundle geometry- baffles dead spaces
Fluid properties -> viscosity, purity
Fouled CW exchanger
External and HCBN fouling
 How to minimize fouling

Design stage ( fouling factors)

Allocation of correct fluids
Control of process parameters
Bundle geometry changes
Frequent cleaning
Advanced methods ( online cleaning, inserts)
 Leaks in S&T Exch
TUBE LEAKS: can be due to
Corrosion of tube side fluid
Corrosion of shell side fluid
Corrosion products- under deposit corrosion
Vibration damage
Erosion damages
Stress cracking
Inherent flaws, material defects
 Causes of tube leak

TUBE LEAK

VIBRATION /STRESS CORROSION DESIGN/ MATERIAL

DEFICIENCY
PITTING
TUBE VIBRATION
UNDER INCORRECT MATERIAL
FLOW PROBLEMS DEPOSIT
CORROSION INCORRECT DESIGN
MECHANICAL
GENERAL POOR MATERIAL
STRESSES THINNING QUALITY
STRESS
CORROSION MECHANICAL STRESSES
CRACKING
 Causes of gasket leak
Wrong gasket type or rating or size
Insufficient tightening
Non-uniform tightening
Thermal stresses across fasteners- differential
thermal expansion or contraction
Thermal shocks
Over pressurization
 Causes of roll joint leaks
Insufficient expansion
Improper cleaning of tubes & tube sheet holes
Damaged grooves of tube sheet hole
Thermal shocks
Poor inspection
Poor weld quality in case of seal welded or
strength welded joints
Over pressurization
 How to identify leaks?
Leak is suspected when intermixing of shell side
and tube side fluids is observed. Normally, if
leakage rate is very high, assume tube leak.
Gasket leaks can be moderate and roll leaks
can be less in amount
1) U TUBE EXCHANGER:
For tube leaks as well as roll leaks drop bonnet,
pressurize shell side.
Gasket leaks can be visible outside
 How to identify leaks- cont’d
2) FLOATING HEAD EXCHANGERS:
There are 5 gaskets in FH exchanger. 4 gaskets
are visible and hence leak is visible
If no leaks are there, drop dome cover,
pressurize tube side and check for floating head
gasket leak.
For tube leak/ roll leak identification, use TEST
RINGS on floating head side and pressurize
shell side
 Causes of corrosion
Corrosion of shell side and tube side can be
due to any / combination of following:
Chlorides: can corrode CS materials at any
temperature  pitting corrosion
Chlorides can result in Stress corrosion
cracking in SS materials under favorable
stressed conditions and temperature
Acids: organic / inorganic acids, wet H2S,
carbonic acids, formic acids  low pH
Alkalies: caustic high pH
Inorganic substances: Sulphur, NH4Cl
Causes of corrosion-cont’d
Amines can corrode non-ferrous materials
Galvanic corrosion: dissimilar metals 
mostly due to design problems
General corrosion: uniform thinning
oxidation ( rusting)
Erosion/ corrosion due to high velocity(
turbulence) , high concentration of some
inorganic salts ( NH4HS)
Under deposit corrosion pitting (localized)
High temperature oxidation
De alloying
 Vibration problems
Vibration could be due to:
Geometry ( design) problem and/or
Process conditions
Vibration can result in:
Tube to tube collision-> wear and thinning
Baffle hole enlargement & tube thinning
Tube breakage near tube sheet
Material defect propagation
Acoustic resonance
 Vibration problems-cont’d

Prone areas:
Nozzle entrance, Near tube sheet,
Unsupported length between baffles, U
bends

How to minimize vibration problems ?

Operating for the purpose intended.
Proper flow conditions
Design/ geometry modifications
 Flow-induced vibration
Two types - RESONANCE and INSTABILITY
Resonance occurs when the natural frequency
coincides with a resonant frequency
Fluid elastic instability
Both depend on span length and velocity

Resonance Instability
Tube displacement

Velocity Velocity
 Avoiding vibration
Inlet support baffles - partial baffles in first few tube
rows under the nozzles
Double segmental baffles - approximately halve cross
flow velocity but also reduce heat transfer coefficients
Patent tube-support devices
No tubes in the window (with intermediate support
baffles)
J-Shell - velocity is halved for same baffle spacing as
an E shell but decreased heat transfer coefficients
 Avoiding vibration (cont.)

Inlet support Double-segmental baffles

baffles
Intermediate baffles

Windows
with no tubes Tubes

No tubes in the window - with intermediate support

baffles
 Key fabrication steps
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
Painting
Documentation
Packing / Protection / Dispatch
 Various Testing/Examinations
Used
Visual Examination
Dye Penetrant Examination
Magnetic Particle Examination
Radiographic Examination
Ultrasonic Examination
Check Tests (Chemical, Mechanical, Special Tests)
Tests for determining pullout load ‘Fr’ value
Pneumatic Tests
Hydraulic Tests
Special Tests (IGC, NACE related, Hardness, Eddy
Current Testing, Helium Leak test Etc.)
Pre-shipment checks
 Maintenance Activities
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
 Steps of retubing
Cut tube and clean the tube sheet holes thoroughly
Do mock up test at workshop
Select the required % expansion for retubing -CES
Measure tube OD, ID and tube sheet hole diameters.
Insert the tubes. Set 3 mm max projection outside tube sheet.
Then expand the tubes by expander tool.
Measure final expanded ID. Calculate the % expansion.
7-8% for CS, 4 to 5% for SS and non ferrous
Expansion in % will be the following x 100

(Tube ID after expn-tube ID before expn-Tube hole dia+tube

OD) /(Tube OD- Tube ID before expan)
Points regarding hydrotest

Isolate all instrument connections

Be sure of hydrotest pressure (1.3 x DP)
Pressure gages – calibrated, proper range
Venting thru highest point
Pressurize from bottom in steps
Go to test Pr, hold 10 min, then come to 2/3 TP
Hold for 30 min, then vent from top
After complete venting, drain from bottom
Drying and preservation
 SITE INSTALLATION

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
Passivation for future use
 Inspection related
Maintain history (of failures, reliability issues)
Recommend repair, replacement based on
inspection findings
Recommend insurance spares
Resolve corrosion, other degradation issues
through TRIPOD
Fulfill statutory requirements (as applicable) –
IBR , Factory Act
 ORDERING INFORMATION
We provide : PR / PO / Datasheet / Drawings /
Other relevant Specifications (Licensor`s or
client`s specifications)
Supplier provide: QAP / ITP, Stage, Final
Inspections reports
Third party inspection agency
Shall be as per Heat Exchanger Specification
Sheet
Performance / Construction details, MOC
 Pre-order requirements
Vendor survey
Enlistment
Monitoring performance
Appraise purchase department
Review technical bids
Cost of Heat Exchangers
Size / type of Heat Exchanger
Material of construction
Type of tube to tube sheet joints
Inspection, NDT requirements based on
severity of service
Imported / indigenous
Location of Manufacturer vs. user
Government / statutory regulations (IBR Etc.)
Quantity, lead time
 Rule of thumb on costing
Price increases strongly with shell diameter/number of
tubes because of shell thickness and tube/tube-sheet
fixing
Price increases little with tube length
Hence, long thin exchangers are usually best
Consider two exchangers with the same area: fixed
tube sheet, 30 bar both side, carbon steel, area 6060 ft2
(564 m2), 3/4 in (19 mm) tubes
Length Diameter Tubes Cost
10ft 60 in 3139 $112k (£70k)
60ft 25 in 523 $54k (£34k)
AIR FIN COOLERS
 What are Air fin coolers
Air fin coolers are heat transfer equipment used for
removing heat from process fluid to the atmosphere
for:
Cooling or
Condensing ( by removing latent heat of vaporization)
or
Partial condensing
The Air fin cooler assembly consists of
Tube bundle for process fluid flow and heat transfer
Fan assembly for providing air flow to remove heat
Significance of Different Types of Heat Exch.
Fin Fan Cooler
No shell required, Header ends similar shell & tube
type.

Application Best Suited:

High level of heat removal is required
Where cooling water not available.
Where ambient temp is low

Limitations:
Problem of frequent fouling and corrosion.
Higher investment
4 to 10 times more ground space in shell & tube type
 Mechanical components
Tubes, tube supports
Inlet & outlet header boxes ( tube sheet , plug sheet)
Header plugs with gaskets
Side covers, air seals
Plenum and plenum covers
Louvres
chimneys
Steam coils
Drive unit:
Fan assembly
Motor and Gear box/ belting, vibration switches
 Materials of construction
Tubes and headers with header plugs:
Carbon steel
Killed CS - H2 and wet H2S services
Chrome-Moly steels
Stainless steels
Fins:
Aluminium
Structures, plenum, fan rings, tube supports
Structural CS with galvanising
Gaskets: plain metal gaskets
 Air-Cooled Heat Exchangers
Forced-draft
– Air forced across tube bundle by fan located in
air plenum below bundle. (Fin fan coolers)

Induced-Draft
– Fan located above hood covering tube bundle.
– Air pulled across tube bundle and exhausted
through hood. (PTA Air fin coolers)

Humidified Forced-Draft
– Air humidified before forced across tubes.
– Evaporation draws heat from air and cools air
below temperature of process fluid.
 Air-Cooled Heat Exchangers
Hood or Plenum Fan Ring
Fan
Return
Inlet Headers
Nozzles

Inlet
Headers

Outlet
Headers

Outlet
Nozzles Tube Bundle

Drive Assembly

Supports

Horizontal Tube, Induced-Draft Air-Cooled Heat Exchanger

 Typical Air-Cooled Heat Exchanger
Lifting Lug Air Seal
Tube Keeper
(top)
Air Seal Header

Tube
Nozzle Air Seal

Header Fins
Tube spacer Side Frame
Tube Support
(bottom)
 Air-Cooled Heat Exchangers

Inlet Nozzles Tube Bundle

Return
Header(s)

Inlet
Headers
Outlet
Headers

Outlet
Nozzles

Fan Plenum
Supports
Fan Ring
Drive
Assembly

Typical Forced-Draft Air-Cooled Heat Exchanger

 Air-Cooled Heat Exchangers
Hot Air

Tube Process Nozzle

Bundle
Partition Plate
Header
Header

Fine Water Mist

Plenum Process Nozzle
Chamber
Water Header
Nozzles (above
fan Typical)
Forced
Draft Fan

Water Header
Nozzles (below
fan Sometimes)

Humidified Forced-Draft Heat Exchanger

Types of arrangement of
fan
General arrangement
Types of arrangement of
fan
Air Fin Coolers
 Types of drafts
FORCED DRAFT:
Fan is placed below bundle
Low HP
Possibility of recirculation of hot air
Easy accessibility to motors
Lesser air distribution compared to induced draft
INDUCED DRAFT:
Better draft and hot air is not recirculated
Poor accessibility for maintenance
Fins protected
Higher HP
 Drive/plenum types

M
G M

M
Transition plenum Box type plenum
 Types fan and fan drives
FIXED PITCH
Pitch can be varied only on stoppage, cheaper
VARIABLE PITCH
Automatic controlled. Save power , better control,
costly
FAN DRIVE:
Belt driven
Gear box driven
MOTOR:
Fixed speed: moderate control
Variable speed: better temp control, cost, save power
 Purpose of Tube to
Tubesheet joint
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 tubes.
 Types of tube-tubesheet joint
Expanded joint
Expanded tube joint is the tube
to tube sheet joint achieved by
mechanical or explosive
expansion of the tube into the
tube hole in the tubesheet.
Types of tube-tubesheet joint
Strength weld is one in which the design strength of the
weld is greater than or equal to the maximum allowable
axial tube strength. A strength weld shall be designed
to transfer all of the longitudinal, mechanical and
thermal axial loads in either direction from the tube to
the tubesheet as well as provide tube joint leak
tightness.
Types of tube-tubesheet joint
Seal weld is used to supplement an expanded tube joint
to ensure tube joint leak tightness.
Recommended to use for following cases where
1. intermixing of shell and tube side fluid causes safety hazards.
2. Lethal fluids are used.
 Tube to tube sheet joint
parameters
Tube MoC, hardness
Tube sheet MoC, hardness
Groove shape
Cleanliness of tube and tubesheet
Type of expander, torque values
Amount of expansion
4-5% for SS
7-8% for CS
10-12% for old tubes re-used
Bundle types
Header types
 Removable bonnet header
Easy cleaning
Easy access to tubes
Header only or tube sheet
can be replaced
Gasket is big and uniform
tightening is reqd
Design for long flanges is
difficult for high
temperatures and pressures
Removal of piping for
opening
 Removable cover plate
header
Easy cleaning
Easy access to tubes
Gasket is big and uniform
tightening is reqd
Design for long flanges is
difficult for high
temperatures and
pressures
 Plug type header
Easy cleaning of tubes
No long flanges and long
gaskets
Selected tubes can be
attended
High pressure design
possible
Good for H2 service
Header cleaning is difficult

SPLIT TYPE HEADER

 Finning types
Embedded ( G type)
Helical groove is cut on tube & fins are wound
Displaced groove metal is forced on each side of fin
Extruded type:
Fins are extruded from outer Aluminium tube
Footed (L) type
Fins are tension wrapped over the tube
Each fin butts against the adjacent fin
BIMETALLI
"G" "L" WRAP-
C
EMBEDDED ON/
EXTRUDED
Maximum
300°C/570° 400°C/750° 120°C/250°
working
F F F
temperature:
Atmospheric
corrosion Excellent Poor Acceptable
resistance:
Mechanical
Excellent Acceptable Poor
resistance:
Price index: 125 105 100
 Fin types

•.
 Routine checks of fin
coolers
Tube bundle:
Check for any visual leaks from tubes or header plugs
Check louvers for operability
External fouling / bowing of tubes
Drive unit:
Vibration of fans
Check belting for cracks/ looseness
Check fan blades for deflection
Check hubs for any cracks
Check all fasteners
Lubrication
 Header arrangement types
D type:
Low pressure drop
Uneven two phase
Even single phase
Piping unsymmetrical

E type
Better symmetry
Better even flow in two phase
Slightly higher pressure drop
 Header arrangement types
C type:
High pressure drop
Best even distribution
Costly but very symmetrical
 Control of fin fan coolers

1. Manually operated louvers.

2. Electrically or pneumatically operated louvers.
3. Pneumatically actuated automatic variable-
pitch fans.
4. Variable-frequency fan drives.
5. Warm-air recirculation systems for
freezing/pour point control in cold climates.
6. Steam coils.
 Relevant standards
API 661
API 632- Winterization
API 631- Noise measurement
ANSI: B1.1 threads
ASNI: B16.5 - flanges
AISC standards - structures
AGMA for gear boxes
ASTM standards for tubes
NACE standards for particular services
Design guidelines as per API 661
Collection of process data
Bundle design temp = 343 max which shall be 28+ maximum
process fluid temp
Design pressure = as per client or inlet pressure + 10% + 25 psi
Calculation of heat transfer coefficients ( air side & process side).
Consider fouling factors also.
Arrive at No of tubes and rows
Select tube length, thickness, OD, pitch as per API guidelines
Select headers . For differential temp> 110 deg, use split header
only
Select drive unit
Louver selection as per specific requirements
Steam coil selection based on calculations
Design parameters required
Process stream flow rate
Process fluid chemical and physical properties
Inlet outlet temperatures
Air side and Process side fouling factors
Inlet pressure and allowable pressure drop
Environment conditions
Design variables:
Air flow rate --> fan capacity
Air outlet temperature/ flow rates
Tube Nos/ rows/ passes
 Key fabrication steps
Material Identification (Pressure parts)
Tube manufacture
Finning
Welding of header box and nozzles
Review of WPS / PQR / Welder Qualification
NDT of header box/ nozzles
Stage and Final Inspections
Tube Mock-up Assembly
Tube expansion / seal welding
Testing
Painting
Documentation
Packing / Protection / Despatch
 Various Testing /
Examinations Used
Visual Examination
Dye Penetrant Examination
Magnetic Particle Examination
Radiographic Examination
Ultrasonic Examination
Check Tests (Chemical, Mechanical, Special Tests)
Tests for determining pullout load ‘Fr’ value
Pneumatic Tests
Hydraulic Tests
Special Tests (IGC, NACE related, Hardness, Eddy
Current Testing, Helium Leak test Etc.)
Pre-shipment checks
 Problems:AFC tube bundle
Tube Internal Fouling:
Indications of fouling:
High process outlet temperature
Higher power consumption of fans
Depends on: process stream properties, corrosion
products, process stream components, coke fines etc
External fouling: Because of external dust/ soot
Tube bowing: flow maldistribution , fouling
Plug header gasket leak:
Improper plug
Damaged threads: mechanical / corroded
Improper tightening
 Problems:AFC tube bundle-cont’d
Tube Leak: Corrosion
Impurities / corrodants in the stream ( Cl-, NH3, H2S, S )
Under deposit corrosion
Erosion -> high velocity/ turbulence/ erodants
Operating beyond operating windows
Improper wash water system
Roll leak:
In adequate expansion
Bad grooves in tube sheet
Thermal shocks
Fouling and resultant severe tube bowing
Poor design ( high differential temperature )
 Maintenance activities
Identify leak type and location: hydrotesting
Attend leak :
– Nozzle gasket leaks - tighten or replace gasket
– Plug gasket leak- re-tighten or replace plug or
replace gasket
– Retubing
– Plugging ( 5% per pass) - taper plug / “J” plug with
welding of tube sheet hole
– re-expansion of tube sheet joint/ re-welding
Cleaning of tubes as per requirements
Install new bundles/ shell as per requirement
Timely modifications in shell side/ tube side as per
CTS/CES/FDC/Licensor requirements
 Steps of retubing
Cut tube and clean the tube sheet holes thoroughly
Do mock up test at workshop
Select the required % expansion for retubing -CES
Measure tube OD, ID and tube sheet hole diameters.
Insert the tubes. Set 3 mm max projection outside tube
sheet. Then expand the tubes by expander tool.
Measure final expanded ID. Calculate the % expansion.
7-8% for CS, 4 to 5% for SS and non ferrous
Expansion in % will be the following x 100

(Tube ID after expn-tube ID before expn-Tube hole dia+tube OD)

( Tube OD- Tube ID before expan)
 Factors affecting performance
/ Reliability
Fouling of bundle
Leaks - gasket leaks or tube leaks
Tube bowing
Flow maldistribution
Process upsets ( flow , temp, pressure)
Wash water system problems
Fan vibrations
Blade problems
Drive unit / transmission unit problems
Ambient conditions
 Inspection activities
Maintain history (of failures, reliability issues)
Recommend repair, replacement based on inspection
findings
Recommend insurance spares
Resolve corrosion, other degradation issues through
TRIPOD
 Pre-order requirements
Vendor survey
Enlistment
Monitoring performance
Appraise purchase department
Review technical bids
 Cost of Air fin coolers
Size / type of bundle, drive unit, transmission
Material of construction
Type of tube to tube sheet joints
Inspection, NDT requirements based on severity of
service
Imported / indigenous
Location of Manufacturer vs. user
Quantity, lead time
 Some Manufacturers

INDIAN
GEA Energy systems
GEI Hamon
FOREIGN
GEA BTT -France
OLMI - Italy
Plate and Frame Exchangers
Plate heat exchanger

Welded
Semi welded
Gasketed

Compact design
Easy maintenance
Used for fouling service
High heat transfer
Costly
 Plate-and-Frame Heat Exchanger
Bin Aout Nozzle
Header
Separating
Sheet
Cin

Corrugated
Sheet Effective
Width

Heat Transfer
Effective Section
Length
A Side Bar

Distributor

Cout Distribution
Section

Ain Bout
A Two-Pass Plate and Frame Flow Arrangement
B
Plate-and-Frame Heat Exchanger

Spiral Flow-Spiral Flow Heat Exchanger

References:
Perry’s Hand Book of Chemical Engineers
Heat Transfer - D Q Kern
Applied Process Design for Chemical and Petrochemical
Industries - Ludwig
TEMA - Design code
ASME - Section VIII Div I
Thank
you