Professional Documents
Culture Documents
Construction
This is the most basic
and the most common
type of heat exchanger
construction.
This type of heat
exchanger consists of a
set of tubes in a container
called a shell.
Tubes are supported in
place by baffles.
The fluid flowing inside
the tubes is called the
tube side fluid and the
fluid flowing on the
outside of the tubes is the
shell side fluid.
OPTIONAL
SHELL
Carbon Steel
HEAD
Cast Iron
TUBES
Stainless Steel
316L Stainless or
Copper
TUBESHEET
Carbon Steel
SEPARATOR
Carbon Steel
Carbon Steel
Stainless Steel
Drawing Symbol:
Construction
In systems where the two fluids
are at vastly different pressures,
the higher pressure fluid is
typically directed through the
tubes and the lower pressure fluid
is circulated on the shell side. The
support plates also act as baffles
to direct the flow of fluid within
the shell back and forth across the
tubes.
Components
Drain inlet:
Shell side fluid enters heat
exchanger
Tube sheet:
Holds the tubes in place and
distributesDrain
the fluid
to the tubes
outlet:
Feedwater inlet:
Tube side
fluid enters heat
exchanger
exchanger
Shell:
Contains shell side fluid
Support Plates:
Tubes:
Feedwater outlet:
Contains the tube side
Working
The principle of operation is
simple enough: Two fluids of
different temperatures are
brought into close contact but
they are not mixing with each
other.
One fluid runs through the
tubes, and another fluid flows
over the tubes (through the
shell) to transfer heat between
the two fluids.
The temperature of the two
fluids will tend to equalize .
The heat is simply exchanged
from one fluid to the other and
vice versa. No energy is added
or removed.
A coil tube heat exchanger is fabricated by rolling a pair of relatively long strips of
plate around a split mandrel to form a pair of spiral passages Channel spacing is
maintained uniformly along the length of the coil passages by means of spacer studs welded
to the plate strips prior to rolling. It can be made with channels 5-25 mm wide, with or
without studs.
The coil channels are welded shut on their ends in order to contain respective fluids.
An overall gasket is applied to the cover. The covers are attached to the coil element by
means of forged hook bolts and adapters. The hook bolt engages the bevel at the back of the
flange ring and the adapter engages the rim at the edge of the cover.
A header is welded on the outer end of each passage to accommodate the respective
peripheral nozzle.
For most services, both fluid flow channels are closed by alternate channels welded at both
sides of the coil plate. In some applications, one of the channels is left completely open, and
the other closed at both sides of the plate. These two types of construction prevent the fluids
from mixing
The coil assembly can be fitted with covers to provide three flow pattern
types:
Both fluids in coil flows; this arrangement can accommodate the media in
full counter flow.
General uses are for liquid to liquid, condensers, and gas coolers.
One fluid in coil flow and the other in axial flow across the coil; general
uses are as
condensers, reboilers, and gas coolers and heaters.
One fluid in spiral flow and the other in a combination of axial and spiral
flow; general uses are as condensers (with built-in after coolers) and
vaporizers.
Construction Material
Spiral plate exchangers are fabricated from any material that
can be cold worked and welded.
Typical construction materials include carbon steel, stainless
steels, Hastelloy B and C , nickel and nickel alloys, aluminum
alloys, titanium, and copper alloys.
Because the turns of the spiral are of relatively large diameter, each turn
must contain its design pressure,
2.
3.
4.
They are normally designed for the full pressure of each passage.
coil plate heat exchangers have a number of advantages over conventional shell and tube exchangers.
The coil tube heat exchanger approaches the ideal in heat exchanger design. Media can be arranged in full
counter flow . Flow characteristics are the same for each medium.
The long passages on each side permit close temperature approaches. Radiation losses are negligible.
The exchanger is well suited for heating or cooling viscous fluids because its UD ratio is lower than that of
tubular exchangers
At a velocity that would be marginal and approaching streamline flow in straight tubes,
good turbulence is realized because of the continuously curving passages.
The scrubbing action of the fluids in each side of the passage tends to flush away deposits
as they form and hence permits the use of low fouling resistance values.
Media cannot intermix; they are isolated by the welded closing on one side of each passage.
The spiral exchanger is compact and requires less installation and servicing space than conventional
exchangers of equivalent surface.
They are easily maintainable. By removing the covers of the spiral exchanger, the entire
lengths of the passages are easily accessible for inspection or mechanical cleaning, if
necessary. Similarly, because of the single passage on each side, the spiral heat exchanger
is readily cleaned with cleaning
Limitations
Besides the pressure limitation noted earlier, the coil plate exchanger also
has the following disadvantages
coil plate exchangers are not recommended for service in which thermal
cycling is frequent. When used for such services, the unit sometimes must
be designed for higher stresses.
The coil type usually should not be used when a hard deposit forms during
operation, because the spacer studs prevent such deposits from being
easily removed by drilling
18
Centrifugal Pump
Centrifugal Pump
Symbol
In Nuclear Reactor, a bulk amount of energy is produced in the fission process and this
energy has to be removed by keeping specific flow rate of reactor coolant. Centrifugal Pumps
are used to provide that specific flow rate.
In the flow of reactor coolant, there is large pressure drop due to Equipment obstacles and
Piping frictional losses hence there is a need of centrifugal pump that will always keep the
reactor coolant in constant dynamic state.
In Nuclear Industry, Centrifugal Pumps that are used, generally deliver high flow rates.
Centrifugal Pump
Centrifugal Pumps
Centrifugal Pumps----3
A centrifugal pump converts the
input power to kinetic energy in
the liquid by accelerating the
liquid by a revolving device - an
impeller.
The most common type is the
volute pump. Fluid enters the
pump through the eye of the
impeller which rotates at high
speed. The fluid is accelerated
radially outward from the pump
chasing.
A vacuum is created at the
impellers eye that continuously
draws more fluid into the pump.
Function of impeller is described
here.
Centrifugal Pumps
A brief description and working phenomena of centrifugal pump is shown in this video
Centrifugal pumps have their fair share of the problems, of course, such as erosion,
corrosion, overheating due to low flow, leakage and overload, they need regular
maintenance.
The energy use of a centrifugal pump can be estimated fairly easily, depending on the
required flow, the height lifted, and the total length of the pipeline.
Reciprocating Pump
Rotary Pump
It can be shown in the chart below
Reciprocating Pump:
A reciprocating pump is a positive
plunger pump. It is often used where
relatively small quantity of liquid is to be
handled and where delivery pressure is
quite large. Its animation can be shown
in the figure.
Rotary Pump:
Rotary vane pump is a positivedisplacement pump that consists of vanes
mounted to a rotor that rotates inside of
a cavity. In some cases these vanes can be
variable length and/or tensioned to
maintain contact with the walls as the
pump rotates. It was invented by Charles
C. Barnes of Sackville, New Brunswick
who patented it on June 16, 1874.
31
Construction
Main parts of a centrifugal fan are
i.
Fan Housing
ii.
Impellers
iii.
iv.
Drive Shaft
v.
Drive Mechanism
Working
Applications
Centrifugal blowers are
used in
Nuclear Power Plants
Thermal Power Plants
Road Tunnels
Wind Tunnels
Mining
Bullet Train cars
36
40
RECIPROCATING COMPRESSOR
Reciprocating compressor is a positive displacement
compressor that deliver gases at high pressure.
In a reciprocating compressor, a volume of gas is drawn into a
cylinder, it is trapped, and compressed by piston and then
discharged into the discharge line. The cylinder valves control
the flow of gas through the cylinder.
R-C COMPONENTRS
Suction valve.
Suction gas jacket.
Piston.
Cylinder.
Discharge valve.
Discharge gas jacket
Types :
Single-stage ( 70 psig to 100 psig)
Two-stage (100 psig to 250 psig)
R-C WORKING
It uses the reciprocating action of
piston inside a cylinder to compress
refrigerant.
The piston moves downward, a
vacuum is created inside the cylinder
and the pressure above the intake
valve is greater than the pressure
below it, the intake valve is forced
open and refrigerant is sucked inside.
After the piston reaches the bottom,
it begins to move upward and the
intake valve closes.
45
Eductor
Eductor uses a motive fluid
to pump another Fluid. Also
referred to as ejectors,
exhausters or siphons.
Principle Of Operation
Principle Of Operation of the
eductor is straightforward
(see Figure ).
Symbol
Principle Of Operation
The motive fluid (gas or liquid)
enters the eductor with high
initial velocity. As the highspeed jet passes through the
nozzle, its pressure decreases in
accordance with Bernoulli's
theorem.
The reduced pressure space
pulls a gas, liquid or solid
material through the suction
port. After mixing, everything
exits through the discharge port
Animatio
n
Applications
Installed near the bottom of a tank and fed
with recirculated fluid from the tank, they
effectively keep solids suspended.
They can blend liquids.
Fed with steam, an eductor can be used for
heating fluids.
3 common
connection
eductor
Performance
An eductor's performance can be controlled by
modulating the motive fluid.
Given a fixed suction pressure and suitable downstream
measurement and feedback, the eductor can provide a
stable vacuum or motive-to-suction flow rate ratio,
which is useful for proportional feeding of two fluids.
Advantages
Low installation and maintenance cost.
They can be fabricated or molded from any metal that's
compatible with the fluids being moved.
It is a self-priming design and can be used in hazardous
areas.
50
What is a Strainer?
A strainer is a device that provides means of
mechanically removing solids from flowing
fluids. This is accomplished by utilizing a
perforated metal, mesh or wedge wire
straining element.
Strainers are employed in pipelines to protect
downstream mechanical equipment such as
condensers, heat
exchangers,
pumps,
compressors, spray nozzles, turbines and
steam traps from detrimental effect of
sediment, rust, pipe scale or other extraneous
debris.
A typical strainer is shown on the right top,
whereas the bottom one is the cross section
of another strainer.
Filter
Strainer
TYPES
FLUSH TYPE
ANIMATION
01
Applications
02
56
HEPA FILTER
HEPA stands for High Efficiency Particulate Air.
symbol
HEPA Filter
Construction
Fibre density
Diameter
Filter thickness.
Working
Uses
61
Activated Charcoal
Charcoal is carbon.
Activated Carbon Filters are used for purification of saluted gas, wastes and
organic materials that give undesirable chlorine, color, taste and smell to
water.
AC is like coal but a material with very wide surface area (1000-1500 cubic
meter / gr).
67
Pressuriser in a pressurized water nuclear power plant primary loop, counteracts the transients in
pressure and temperature. When the pressure in the primary loop drops due to decrease in
temperature by virtue of increase in plant power demand, the water from Pressuriser flows in to the
hot leg through the surge line connected at the bottom of Pressuriser, the electrical heaters overcome
the enthalpy drop, increase the temperature and pressure again by adding additional heat energy.
Voltage
Up to 660 VAC
Maximum Frequency
50 and 60 Hz
Power
Design Pressures
Design Temperatures
Quality Class
PROPORTIONAL HEATERS: These heaters are connected to proportional controllers, which adjust the
heat input to account for steady-state losses and to maintain the desired steam pressure in the
Pressuriser. They operate only when the pressure falls to 2225 psig without insurge or the pressures are
2200 psig or low.
BACKUP HEATERS: The backup heaters are connected to on-off controllers. These heaters are normally
de-energized, but are automatically turned on by a low Pressuriser pressure signal. They turn off when
the pressure of 2275 psig is achieved.
HEATERS PROTECTION/SAFETIES: The pressurizer level heating trip is provided as a safety feature to
avoid damaging of electric heaters under excessive overheating which is certain if they are exposed to
the vapors because in vapor phase heat transfer reduces sharply which leads to a sharp rise in heater
temperature. A low-low Pressuriser water level signal (23.1% instead of 53%) de-energizes all heaters
ELECTRICAL POWER CONSUMPTION: The electrical power input for NPP Pressuriser heating
requirements varies from 400 KW to 1,500 KW or more depending upon size and design of Pressuriser
and the nuclear reactor itself. A Pressuriser heater for a 900 MW power plant reactor offers the thermal
72
Steam Trap
A steam trap is an automatic valve that allows
the condensate to discharge but traps or prevent
the flow of steam.
Types
1. Mechanical steam traps
Types
2. Temperature steam traps
Types
3. Thermodynamic steam traps
Work on the difference in response
to velocity change in flow of
compressible and incompressible
fluids. As steam enters, static
pressure above the disk forces the
disk against the valve seat. The static
pressure over a large area
overcomes the high inlet pressure of
the steam. As the steam starts to
condense, the pressure against the
disk lessens and the trap opens to
allow condensate out.
78
Bellows
Continued
Covers (Shrouds):
used to prevent damage
during installation and
operation or when welding
is going to be Perform
Tie Rods:
usually bars or rods,
attached to the expansion
joint assembly and are
designed to absorb pressure
thrust loads and other
extraneous forces
Continued
Limit Rods:
Limit rods are used to protect the bellows
from movements in excess of design.
They dont contain pressure thrust during
normal operation.
Control Rods:
They are attached to the expansion joint
assembly with primary function is to
distribute the movement between the
two bellows of a universal expansion
joint. They are not design to restrain
bellows pressure thrust
Connector Movements
Axial movement is the
change in dimensional
length of the bellows from
its free length in a direction
parallel to its longitudinal
axis.
Lateral movement is the
relative displacement of one
end of the bellows to the
other end in a direction
perpendicular to its
longitudinal axis (shear).
Continued
Angular movement is the
rotational displacement of the
longitudinal axis of the
bellows toward a point of
rotation
Bellow
Testing
Bellow
Forming
Forming
Machine
90
Spray Nozzle
A spray nozzle is a precision device that facilitates
dispersion of liquid into a spray.
Spray is a dynamic collection of drops dispersed in a
gas. The process of forming a spray is known as
atomization.
Spray Nozzle
Spray Nozzle
Spray Nozzle
Spray nozzles are used for three purposes: to
distribute a liquid over an area, to increase liquid
surface area, and create impact force on a solid
surface.
Spray nozzles can be categorized based on the energy
input used to cause atomization, the breakup of the
fluid into drops.
Spray Nozzle
Applications
Disadvantage
A portion that are atomized, lost into the air due
to weightlessness. This results in high usage (cost)
and extra cost for pumping the material.
Spray nozzles are prone to clogging and abrasion
at the nozzle mouth.
Spray Nozzle
Symbol
Sparger
Spargers are ideal for applications requiring gas-to-liquid contacting because of the
media's uniform porosity. The key to high-efficiency sparging is fine bubble
propagation, which provides maximum surface area for effective "mass transfer"
while using less gas, resulting in cost reduction.
Sparger Nozzles
Sparger Applications
Sparger nozzles are designed to be submerged in the liquid for heat and mass
transfer. It is recommended for use in the cases:
1.
Where it is desired to start heat and mass transfer from a shallow level.
2.
Where uniform agitation and heat and mass transfer is required over a large,
shallow tank area.
3.
4.
Where solids in the liquid might tend to clog the small passages.
5.
Animation Ref.
Video Ref.
103
Introduction
Quick-disconnect couplings provide a
means of quickly disconnecting a line
without the loss of hydraulic fluid or
entrance of air into the system.
Each coupling assembly consists of two
halves, held together by a union nut. Each
half contains a valve, which is held open
when the coupling is connected.
This action allows fluid to flow in either
direction through the coupling.
When the coupling is disconnected, a spring
in each half closes the valve, preventing the
loss of fluid and entrance of air.
The union nut has a quick-lead thread that
permits connecting or disconnecting the
coupling by turning the nut. The amount the
nut must be turned varies with different
styles of couplings.
107
Principle of Operation
Forward acting discs mount with the concave surface facing the process media. As
pressure increases above the recommended operating pressure, the disc will bulge
until it reaches the maximum tensile strength of the material and ruptures.
Application
Rupture discs are commonly used in petrochemical, aerospace, aviation, defense,
medical, railroad, nuclear, chemical, pharmaceutical, food processing and oilfield
applications.
They can be used as single protection devices or as a backup device for a
conventional safety valve; if the pressure increases and the safety valve fails to
operate (or can't relieve enough pressure fast enough), the rupture disc will burst.
Rupture discs are very often used in combination with safety relief valves, isolating
the valves from the process, thereby saving on valve maintenance and creating a
leak-tight pressure relief solution
They are often used as the primary pressure relief device.
Very rapid pressure rise situations like runaway reactions.
When pressure relief valve cannot respond quick enough.
They can also be used in conjunction with a pressure relief valve to:
Provide corrosion protection for the PRV.
Prevent loss of toxic or expensive process materials.
Reduce fugitive emissions to meet environmental requirements.
Damaged during
Installation
A single stage orifice plate is a device used for measuring the volumetric flow rate. It uses the same principle as a
Venturi nozzle, namely Bernoulli's principle which states that there is a relationship between the pressure of the fluid
and the velocity of the fluid. When the velocity increases, the pressure decreases and vice versa.
DISCRIPTION
A single stage orifice plate is a thin plate with a hole in the middle. It is usually placed in a pipe in which fluid flows.
When the fluid reaches the orifice plate, the fluid is forced to converge to go through the small hole; the point of
maximum convergence actually occurs shortly downstream of the physical orifice, at the so-called vena contracta
point (as shown in the figure below). As it does so, the velocity and the pressure changes. Beyond the vena contracta,
the fluid expands and the velocity and pressure change once again. By measuring the difference in fluid pressure
between the normal pipe section and at the vena contracta, the volumetric and mass flow rates can be obtained from
Bernoulli's equation.
Uses
Orifice plates are most commonly used for continuous measurement of fluid flow in
pipes. A restrictive flow orifice, a type of orifice plate, is a safety device to control
maximum flow from a compressed gas cylinder.
They are also used in some small river systems to measure flow rates at locations where
the river passes through a culvert or drain. Only a small number of rivers are
appropriate for the use of the technology since the plate must remain completely
immersed i.e. the approach pipe must be full, and the river must be substantially free of
debris.
122
128
Flange connection
A flange is an external rib at the end of pipes, valves and other flow devices to assemble them.
Flange Connection is a technology from the hydraulic area, which allows a weld free
connection of hydraulic tubes.
Flanges to be used on all pipe: flanges must have holes for bolts quite separate from the big
hole in the middle of flange.
All flanges must be cast or forged of very best quality iron metal, close grained, free from
blowholes, lumps, cavities, pockmarks, pinpricks and warts. Otherwise we cant use them.
Gaskets are to used to fill space between flanges.
The flange connection system is competing with the welding bonding of hydraulic tubes.
Compared with the welding process the advantages are marked in savings on time and costs.
Expansive procedures like radio graphing and cleaning with anticorrosive agents of the pipe
connection are dispensed with the flange technology. Therefore the technology is also more
environmental friendly and safer than welding.
Contd
Contd
Blind connection