HEAT TRANSFER

PRIME OBJECTIVES:
TO ACHIEVE MAX H.T. RATE PER UNIT SURFACE COMPATIBLE
WITH ECONOMIC FACTORS.
TO SALVAGE MAX HEAT AS IN HEAT EXCHANGERS.
TO MINIMISE HEAT FLUX BY USE OF INSULATION.

MECHANISM OF HEAT TRANSMISSION

CONDUCTION
FOURIERS LAW FOR UNIDIRECTIONAL HEAT FLOW
dQ
= - KA
dT
d
dx
FOR STEADY STATE
dQ
= - KA
dT
dX
CONVECTION:
NEWTONS EQUATION FOR CONV. HT
Qc = hw A (tw t)
THIS EQUATION DEFINSE MEAN CONV. H.T. COEFFICIENT hw WHICH DEPENDS
ON:
hw DEPENDS ON :
1.PHYSICAL PROPERTIES OF THE FLUID : , ..C.K.
2.DIMENSION OF THE APPARATUS
3.VELOCITY OF THE FLUID
4.TEMPR. POTENTIAL
HOT FACE
COLD FACE
5.PHASE CHANGE
(-)dT
TH
dX TC
RADIATION:
STEFAN BOLTZMAN EQ FOR RADIATION
H.T. IS
dQr = dA T4

T
X=0X=X

DISTANCE

HEAT EXCHANGERS:
ADVANTAGE OF SHELL & TUBE EXCHANGERS:
a)
b)
c)

HAS VERY LARGE SURFACE IN RELATIVELY SMALL VOLUME.

CAN BE FABRICATED FROM ALLOY STEELS TO RESIST CORROSION.
CAN BE USED FOR HEATING & CONDENSING ALL KINDS OF FLUIDS.

THEORY OF HEAT EXCHANGE IN SHELL & TUBE EXCHANGERS

Q = K1 A1 (T1 T2)
X1

K1 = h1
X1

= h2

(T1 T2) =

K2
X2
Q
A1h1

(T1 T4) =

A1 T =

T = Q (

Q ( 1 + A1
h1
Aw

Q = U1 A1 T

Kw Aw (T2 T3)
Xw

K1

KW

K2

T1
T2

(T2 T3) = Q Xw (T3 T4) = Q

Aw Kw
A2 h2
1
h1A1

Xw +
Aw Kw

Xw +
Kw

A1
A2

U1 = ( 1

T3
T4

1
)
h2 A2

1 )=Q
h2 U1
A1 X +
A1
K1
Aw Kw

X1

1 )
A2

XW

h2

X2

OPERATON :
COMMISIONING :
FIRST COMMISION COLD FLUID. VENT OUT
AIR BLOCKED INSIDE. BEFORE OPENING O/L BL.
NORMAL CHECKS :
FOR ANY FLANGE LEAKS
FOR TUBE LEAKS IN CASE OF COOLERS
BY KEEPING, VENT OPEN & CHECK FOR OIL.
SURVEYS :
H.E. SURVEYS MEASUREMENT OF SHELL SIDE
& TUBE SIDE FLOWS, I/L AND O/L TEMPR. TO
CHECK FOR OVERALL H.T. COEFF.
TO ASSERTAIN .
DECOMMISSIONING :
FIRST DECOMMISSION HOT FLUID. THEN COLD
FLUID.
DRAIN SHELL & TUBE SIDE
PUT ISOLATION BLINDS.
CLEANING :
RODDING, HYDRO JETTING OR HYDRO
BLASTING (10,000 PSI)
INSPECTION
FOR CLEANLINESS OF INSIDE & OUTSIDE OF THE TUBES.

PRESSURE TEST : (HYDRO TEST)

FIRST SHELL TEST IS DONE TO CHECK FOR TUBE LEAKS :
STEPS :
WATER FILLING & VENTING FOR AIR.
PRESSURISING WITH HYDRAULIC PUMP TO TEST PR. 1.5 TIMES WORKING PR.
AIR BLOWING INSIDE OF THE TUBE FOR DRYNESS, (LEAKY TUBE WILL BE
WET WHICH CONFIRMS LEAK)
CHECKING EACH TUBE FOR ANY DRIPPING OF WATER.
PLUGGING LEAKY TUBE WITH PLUGS ON BOTH ENDS.
CHECKING FOR CHANNEL HEAD LEAK.

TUBE TEST :
1. REMOVE FLOATING HEAD SIDE RING.
2. BOX-UP FLOATING HEAD & CHANNEL COVER.
3. WATER FILLING AND VENTING.
4. PRESSURISING & CHECK FOR LEAKS FROM FLOATING HEAD COVER
AND CHANNEL COVER.
BOX UP
DEBLINDING
COMMISSIONING FIRST COLD FLUID THEN HOT FLUID
HOT BOLTING OF FLANGES.
VENTING AIR POCKET FOR COOLERS AND EXCHANGER FOR
WATER SIDE.

BACK FLUSHING
1.CLOSE COOLING WATER I/L VALVE SLOWLY.
2. OPEN THE BACK FLUSHING VALVE.
3.BACK FLUSH FOR ABOUT 60SECONDS.
4.SLOWLY CLOSE BACK FLUSHING NOZZLE.
5. OPEN COOLING WATER I/L VALVE.

WATER COOLERS
FACTORS CONTRIBUTING TO LOW EFFICIENCY
1. Plugged Tubes
2. Biological Deposits
3. Hardness Deposits
4. Low Cooling Water Inlet Pressure
5. Hydrocarbon Leaks
SCALES MAY BE
METAL OXIDES SULFIDES
ORGANIC MATERIALS ORGANIC POLYMERS
*COKE
* SALT
ETC.,
ORGANIC FOULING
POLYMERISATION OF HIGH MOLECULAR WEIGHT ORGANIC COMPOUNDS.
DEPOSITION OF ABOVE ON H.T. AREA FURTHER POLYMERISE DEGRADE
AND FORM COKE.
REACTION : FREE RADIAL CHAIN REACTION. INITIATED BY METAL
CONTAMINANTS BY OXYGEN CONTAMINANTS OR SIMPLY BY HEATING.

INORGANIC FOULING :
NH4 Cl OVHD COND. BY REACTION WITH NH3
METALLIC SALTS, OXIDES, SULPHIDES ETC.,
SOLUTION TO FOULING :
*MECHANICAL
*CHEMICAL
MECHANICAL : USING FILTERS, REVAMPING EQUIPMENT INTERNALS TO
INCREASE VELOCITY OR TO GIVE BETTER FLOW PATTERN.
CHEMICAL : USAGE OF ANTI-FOULANTS
PREVENTION OF FOULANTS FROM FORMING :
CORP. INHIBITOR, ANTIOXIDANTS . METAL COORDINATORS
PEVENT DEPOSITION OF FOULANTS
SURF (ACE) ACTANTS ACT AS DETERGANTS
POLY FUNCTIONAL
APPLIED IN CONCENTRATION OF 5 TO 100 PPM
SAVINGS DUE TO INCREASED
PRODUCTION/FUEL SAVING/MAINTENANCE COST/OPERATING EFFICIENCY

CRITERIA FOR SELECTING SHELL & TUBE SIDE FLUIDS:

SHELL SIDE FLUID:

CLEAN FLUID
PRESSURE DROP AVAILABLE IS LOW.
IF LARGE VOLUME OF FLUID IS HANDLED.
NORMALLY LOW OPERATING PRESSURE.
TUBE SIDE FUID :
1. CORROSIVE OR FOULING FLUID : AS INSIDE OF THE TUBE CAN BE CLEANED
EASILY & IF CORROSION IS EXCESSIVE THE EXCHANGER CAN BE RETUBED.
2. HIGH PRESSURE CAN BE ECONOMICALLY HANDLED IN THE TUBE SIDE.
3. HIGH TEMP. IN TUBE SIDE ARE LESS COSTLY TO INSULATE., HOWEVER THIS IS
SELDOM GOVERNING FACTOR.

STEAM REBOILER

The controller holding the Re-boiler outlet temperature signals

the control valve to close.
As the control valve closed, the pressure in channel head dropped to 8.5 kg / cm2.
When this pressure dropped the condensate could not drain freely to header.
Hence condensate level started raising.
Submerged tubes are not available for heat transfer.
TRC then opened the steam I/L control valve and the channel head pressure,
increased to 10.5 kg/cm2.
High channel head pressure forced the condensate level to drop and quickly
increased reboiler duty.
The cycle was repeated.
TRC
10.5 kg/CM 2
STEAM
HEADER

CHANNEL
HEAD

Corrective Measure : Remove Control valve in steam

Inlet line and install in condensate line.

8.0 kg/cm2
CONDENSATE
HEADER

STEAM HEARTERS
Condensate Back up into channel Head
Malfunctioning of steam Trap.
Increased pressure in the steam condensate collection Header.
Installation of control valve directly on condensate drain line.
(Introduce an intermediate condensate level drum)
Blown condensate seal
STEAM INLET

RUST LAYER

CONDENSATE
OUTLET

CRITERIANS USED IN HEAT EXCHANGER / COOLER DESIGN.

COOLING FLUID TEMPR WATER O/L > 120oF(49C) CARBONATE

PRECIPITATION AT 140oF(60C).
VELOCITY TO MINIMISE FOULING.
C.W : 3 7.5 ft /sec. CRUDE 6-8 ft / sec
SLURRY OIL IN FCCU 5-10 ft / sec.
ALLOWABLE P
10-15 psi FOR NEW SYSTEM.
=>5 psi FOR RETROFIT NEW EXCHANGER TO AVOID REPLACEMENT OF PUMP
FOULING RESISTANCE
HEAT TRANSFER RESISTANCE DUE TO FOULING INCREASES WITH TIME.
TO HAVE REASONABLE SERVICE PERIOD PROVIDE ADDITIONAL
ALLOWANCE FOR FOULING.

FOULING INFLUENCED BY :

Fluid & Deposit Nature / Heat Sensitivity.

Fluid Temperature.
Tube wall material & finishing.
Fluid Velocity.
Operating time since last cleaning.

ECONOMIC FACTORS FOR CONSIDERING FOULING.

Initial Exch. Cost.

Cleaning Frequency
Cost of cleaning / Production loss.
Fluid Pumping change
Desired return on investment.

CONSTRUCTION SPECIFICATIONS:
1. DESIGN P & T
- Normal / Alternate Condition.
- Start up / Shut Down / Emergency. Condition.
- Pump shut off pr.
- System Pr. / Relief capability.
2. TUBES
- Bundle : Geometry of bundle component
- Length : L P
- Economical. L
- Dimensions & Pitch
- size or 1
- pitch
3. BAFFLES : Divert Flow
17.25% - Highest H.T.Rate

OPTIMISATION OF H.E. TRAIN

1. SYNTHESIS OF H.E. NET WORK
- Matching & Sequencing Hot & Cold Fluid to Extract
max. heat from hot Fluid.
- INFORMATION REQUIRED :
- Flow rate - initial temper
- Final requirement of temp. For different streams.
- Use of external utilities like C.W / Steam.
2. OPTIMISATION OF INDIVIDUAL EXCHANGER
FACTORS :
- No. of S & T Passes.
- Interchange of Shell & Tube Fluids.
- Tube size, & Pitch
- Max. Shell dia
- Baffle Spacing.

MAIN OBJECTIVE : TO REALISE MAX H.T. COEFFICIENT.

CONSIDER WHICH ONE FIRST ?
- OF COURSE NET WORK . AS:
- FOR IND. HE U depends on Fluid Property Hence P,T, & Geometry i.e.
size & load.
- P, T Condition Possible only after deciding Net Work / Placement of H.E in the
train.

IMPORTANT POINTS TO BE CONSIDERED:

1.

H.E Train Sub-System among pump, Furnace etc.

This makes the net-work complicated.

2.

Process Condition.
Fixed Temp. / Heat Load consideration.
Contamination Problem.
SOR / EOR Conditions.
H.T. Coefficient h for heavier Prod.
Ease of operation & maintenance.

3.

Feed Stood Flexibility

Heat load shifting from light Product exchanger to Hy. product
Exchanger. While processing Hy.crude.

4.

EQUIPMENT LIMATION :
- P - pumping Requirement Variation.
- Max. Area in a shell - in case exceeds parallel exchanger used.
- Preheat temp. Furnace Limitation.
- Inlet Pr. Increased to suppress Vapor for distribution.

5.

HEAT INTEGRATION :
- BFW Heating / L.P. Steam Prodn.
- Reboiling other tower fluid. Etc.,

6.

CONFIGURATION SELECTION:
- TEMP. DIFF.
- HEAT AVAILABILITY
- Temp. Cross over will not be a controlling factor for the amount
of Heat Exchanged.

7.

ECONOMICS:

Q:What is the Basic objective of Heat Exchanger

Q:If the number of passes are increased, what will happen to P, Velocity &
heat Transfer.
Q:Types of Heat Exchanger.
Process Wise
Mechanical Type
Q:Main Reason for lesser heat transfer
Q:Three types of Heat Transfer
Q: Water & Hydrocarbon which should be on Tube side.
Q: Different parts of exchanger
Q:What is tieRod ?

Q: FIND LMTD
I/L
O/L
-------------------------------------------------------------------------------------------------------------------Hot Fluid
200
150
Cold
32
45
-------------------------------------------------------------------------------------------------------------------Q:Explain the Terms
Q

= MCpT

UAT

Q, M, Cp, T, U, A, T
Q:CW Temp. increase indicates ------- in cooling water flow. increase / Decrease.
Q:More efficient. Co-current/Counter current