Understanding Heat Exchanger Reading 01

My Reading on Heat Exchanger
Reading 01- An Introduction

for my Aramco AOC’s QM31 Exam Preparations
09th May 2018
Charlie Chong/ Fion Zhang

闭门练功

Heat Exchanger

Heat Exchanger

Heat Exchanger

Heat Exchanger

Heat Exchanger
Heat Exchanger

Heat Exchanger

Heat Exchanger

Heat Exchanger

Fion Zhang at Xitang
9th May 2018

Charlie Chong/ Fion Zhang http://greekhouseoffonts.com/
The Magical Book of Tank Inspection ICP

Heat Exchanger
https://en.wikipedia.org/wiki/Heat_exchanger
A heat exchanger is a device used to transfer heat between a solid object and
a fluid, or between two or more fluids. The fluids may be separated by a solid
wall to prevent mixing or they may be in direct contact. They are widely used
in space heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing,
and sewage treatment. The classic example of a heat exchanger is found in
an internal combustion engine in which a circulating fluid known as engine
coolant flows through radiator coils and air flows past the coils, which cools
the coolant and heats the incoming air. Another example is the heat sink,
which is a passive heat exchanger that transfers the heat generated by an
electronic or a mechanical device to a fluid medium, often air or a liquid
coolant.
Keywords:
transfer heat between a solid object and a fluid (fluids).

Flow arrangement
There are three primary classifications of heat exchangers according to their
flow arrangement:
 In parallel-flow heat exchangers, the two fluids enter the exchanger at the
same end, and travel in parallel to one another to the other side.
 In counter-flow heat exchangers the fluids enter the exchanger from

opposite ends
ends. The counter current design is the most efficient
efficient, in that it
can transfer the most heat from the heat (transfer) medium per unit mass
due to the fact that the average temperature difference along any unit
l
length
th is
i higher.
hi h See
S countercurrent
t t exchange.
h
 In a cross-flow heat exchanger,

g , the fluids travel roughly
g yp perpendicular
p to
one another through the exchanger.
 Others

Countercurrent (A) and parallel (B) flows

Cross Flow Heat Exchanger

Counter, Parallel and Cross Flow Heat Exchanger

Countercurrent one pass tube side

Countercurrent and parallel Two Pass Tube Side

Countercurrent and parallel 2 Pass Tube Side

Countercurrent and parallel 2 Pass Tube Side
Parallel
flow
Counter
flow

For efficiency, heat exchangers are designed to maximize the surface area of
the wall between the two fluids, while minimizing resistance to fluid flow
through the exchanger. The exchanger's performance can also be affected by
the addition of fins or corrugations in one or both directions, which increase
surface area and may:
 channel fluid flow
 or induce turbulence.
The driving temperature across the heat transfer surface varies with position,
but an appropriate mean temperature can be defined. In most simple systems
this is the "log mean temperature difference" (LMTD). Sometimes direct
knowledge of the LMTD is not available and the NTU method is used.

LMTD:
The logarithmic mean temperature difference (also known as log mean
temperature difference or simply by its initialism LMTD) is used to determine
the temperature driving force for heat transfer in flow systems, most notably in
heat exchangers. The LMTD is a logarithmic average of the temperature
difference between the hot and cold feeds at each end of the double pipe
exchanger. The larger the LMTD, the more heat is transferred. The use of the
LMTD arises straightforwardly from the analysis of a heat exchanger with
constant flow rate and fluid.
NTU:
The Number of Transfer Units (NTU) Method is used to calculate the rate of
heat transfer in heat exchangers when there is insufficient information to
calculate the Log-Mean Temperature Difference (LMTD). In heat exchanger
analysis, if the fluid inlet and outlet temperatures are specified or can be
determined by simple energy balance, the LMTD method can be used; but
when these temperatures are not available The NTU or The
effectiveness method is used.

Is that only air cooled heat exchanger finned?




Types
■ Double pipe heat exchangers
are the simplest exchangers used in industries. On one hand, these heat
exchangers are cheap for both design and maintenance
maintenance, making them a good
choice for small industries. On the other hand, their low efficiency coupled
with the high space occupied in large scales, has led modern industries to
use more efficient heat exchangers like shell and tube or plate. However,
since double pipe heat exchangers are simple, they are used to teach heat
exchanger design basics to students as the fundamental rules for all heat
exchangers are the same.

Double Pipes Heat Exchanger- Simplest
Counter
flow

Double Pipes Heat Exchanger- Simplest

■ Shell and tube heat exchanger
Shell and tube heat exchangers consist of series of tubes. One set of these
tubes contains the fluid that must be either heated or cooled. The second fluid
runs over the tubes that are being heated or cooled so that it can either
provide the heat or absorb the heat required. A set of tubes is called the tube
bundle and can be made up of several types of tubes: plain, longitudinally
finned, etc. Shell and tube heat exchangers are typically used for high-
pressure applications (with pressures greater than 30 bar and temperatures
greater than 260 °C).
C). This is because the shell and tube heat exchangers are
robust due to their shape.
Severall th
S thermall d
design
i features
f t mustt be
b considered
id d whenh d designing
i i ththe
tubes in the shell and tube heat exchangers: There can be many variations on
g Typically,
the shell and tube design. yp y, the ends of each tube are connected to
plenums (sometimes called water boxes) through holes in tubesheets. The
tubes may be straight or bent in the shape of a U, called U-tubes.

Counter
flow

Straight Tube Heat Exchanger
( One pass tube side)
Shell side
nozzle

Straight Tube Heat Exchanger
( Two pass tube side)
Channels
Channel
Channels
Nozzles
Pass
divider
Plenum / Water
Box
This is straight tube, two pass
tube side. Other configuration
Channel include U-tube two pass tube side
Cover

U-Tube Heat Exchanger
( Two pass tube side)
Plenum (water-box) or
Channel?
The U- tube bundle

(plain)

Plenums/ Channel
Plenum (water-box)
or Channel?

 Tube thickness: The thickness of the wall of the tubes is usually
determined to ensure:
1. There is enough room for corrosion
2. That flow-induced vibration has resistance
3. Axial strength
4. Availability of spare parts
5. Hoop strength (to withstand internal tube pressure)
6. Buckling strength note1 (to withstand overpressure in the shell)
 Tube length: heat exchangers are usually cheaper when they have a
smaller shell diameter and a long tube length. Thus, typically there is an
aim to make the heat exchanger as long as physically possible whilst not
exceeding production capabilities. However, there are many limitations for
this, including space available at the installation site and the need to
ensure tubes are available in lengths that are twice the required length
(so they can be withdrawn and replaced). Also, long, thin tubes are
difficult to take out and replace.
Note 1: In science, buckling is a mathematical instability that leads to a failure mode.

When a structure is subjected to compressive stress, buckling may occur.
Buckling is characterized by a sudden sideways deflection of a structural member.

 Tube thickness: The thickness of the wall of the tubes is usually
determined to ensure:
1. There is enough room for Other considerations include the shorter
corrosion
length tube increase the diameter of the
2. That flow-induced vibration has
tube resistance
bundle and the shell, consequently
3. Axial strength the shell material thickness is increase.
4. Availability of spare parts
5. Hoop strength (to withstand internal tube pressure)
6. Buckling strength note1 (to withstand overpressure in the shell)
 Tube length: heat exchangers are usually cheaper when they have a
smaller shell diameter and a long tube length. Thus, typically there is an
aim to make the heat exchanger as long as physically possible whilst not
exceeding production capabilities. However, there are many limitations for
this, including space available at the installation site and the need to
ensure tubes are available in lengths that are twice the required length
(so they can be withdrawn and replaced). Also, long, thin tubes are
difficult to take out and replace.
Note 1: In science, buckling is a mathematical instability that leads to a failure mode.

When a structure is subjected to compressive stress, buckling may occur.
Buckling is characterized by a sudden sideways deflection of a structural member.

Pressure Vessel- Heat exchanger

 Tube pitch: when designing the tubes, it is practical to ensure that the
tube pitch (i.e., the centre-centre distance of adjoining tubes) is not less
than 1.25 times the tubes' outside diameter. A larger tube pitch leads to a
larger overall shell diameter, which leads to a more expensive heat
exchanger.
 Tube corrugation: this type of tubes, mainly used for the inner tubes (?) ,
increases the turbulence of the fluids and the effect is very important in
the heat transfer giving a better performance.
1.25 x d min
Tube Corrugation - Increases the turbulence of the fluids and the effect is
very important in the heat transfer giving a better performance.

 Tube Layout: refers to how tubes are positioned within the shell. There
are four main types of tube layout, which are:
■ triangular (30°),
■ rotated triangular (60°),
■ square (90°) and
■ rotated square (45°).
The triangular patterns are employed to give greater heat transfer as they
force the fluid to flow in a more turbulent fashion around the piping.
Square patterns are employed where high fouling is experienced and
cleaning is more regular.

 Baffle Design: baffles are used in shell and tube heat exchangers to:
# 1 Direct fluid across the tube bundle.
# 2 They run perpendicularly to the shell and hold the bundle,
# 3 Preventing the tubes from sagging over a long length.
# 4 They can also prevent the tubes from vibrating.
The most common type of baffle is the segmental baffle. The semicircular
segmental baffles are oriented at 180 degrees to the adjacent baffles
forcing the fluid to flow upward and downwards between the tube bundle.
Baffle spacing is of large thermodynamic concern when designing shell
and tube heat exchangers. Baffles must be spaced with consideration for
the conversion of pressure drop and heat transfer. For thermo economic
optimization it is suggested that the baffles be spaced no closer than 20%
of the shell’s inner diameter. Having baffles spaced too closely causes a
greater pressure drop because of flow redirection.

Consequently, having the baffles spaced too far apart means that there may
be cooler (or hot?) spots in the corners between baffles. It is also important to
ensure the baffles are spaced close enough that the tubes do not sag.
The other main type of baffle is the disc and doughnut baffle, which consists
of two concentric baffles. An outer, wider baffle looks like a doughnut, whilst
the inner baffle is shaped like a disk. This type of baffle forces the fluid to
pass around each side of the disk then through the doughnut baffle
generating a different type of fluid flow.
Fixed tube liquid-cooled heat exchangers especially suitable for marine and
harsh applications can be assembled with brass shells, copper tubes, brass
baffles, and forged brass integral end hubs.

Segmented, Disk & Doughnut and Orifice Baffles.

Heat Exchanger Baffles
 #1 Direct fluid across
the tube bundle.
 # 2 They run
perpendicularly to the
shell and hold the
bundle,
 # 3 Preventing the
tubes from sagging over
a long length.
 # 4 They can also
prevent the tubes from
vibrating.
 #5 Forcing the fluid to
flow upward and
downwards between the
tube bundle, creating
turbulent?

Heat Exchanger Baffles
0.20 x D min
For thermo economic optimization it is suggested

that the baffles be spaced no closer than 20% of the
shell’s inner diameter. Having baffles spaced too
closely causes a greater pressure drop because of
flow redirection.

■ Plate heat exchangers
Another type of heat exchanger is the plate heat exchanger. These
exchangers are composed of many thin, slightly separated plates that have
very large surface areas and small fluid flow passages for heat transfer
transfer.
Advances in gasket and brazing technology have made the plate-type heat
exchanger increasingly practical. In HVAC applications, large heat
exchangers of this type are called plate-and-frame; when used in open loops,
these heat exchangers are normally of the gasket type to allow periodic
disassembly cleaning,
disassembly, cleaning and inspection
inspection. There are many types of permanently
bonded plate heat exchangers, such as dip-brazed, vacuum-brazed, and
welded plate varieties, and they are often specified for closed-loop
applications
li ti suchh as refrigeration.
fi ti Pl
Plate
t hheatt exchangers
h also
l diff
differ iin th
the
types of plates that are used, and in the configurations of those plates. Some
plates may
p y be stamped
p with "chevron",, dimpled,
p , or other p patterns,, where
others may have machined fins and/or grooves.

When compared to shell and tube exchangers, the stacked-plate
arrangement typically has lower volume and cost. Another difference between
the two is that plate exchangers typically serve low to medium pressure fluids,
compared to medium and high pressures of shell and tube. A third and
important difference is that plate exchangers employ more countercurrent
flow rather than cross current flow, which allows lower approach temperature
differences, high temperature changes, and increased efficiencies.

Plate heat exchangers



Shell And Tube Heat Exchanger
https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger
A shell and tube heat exchanger is a class of heat exchanger designs. It is the
most common type of heat exchanger in oil refineries and other large
chemical processes, and is suited for higher-pressure applications. As its
name implies, this type of heat exchanger consists of a shell (a large pressure
vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and
another fluid flows over the tubes (through the shell) to transfer heat between
the two fluids. The set of tubes is called a tube bundle, and may be composed
of several types of tubes: plain, longitudinally finned, etc.

Fluid Flow Simulation for a shell and tube style exchanger; The shell inlet is
at the top rear and outlet in the foreground at the bottom

Theory and application
Two fluids, of different starting temperatures, flow through the heat exchanger.
One flows through the tubes (the tube side) and the other flows outside the
tubes but inside the shell (the shell side). Heat is transferred from one fluid to
the other through the tube walls, either from tube side to shell side or vice
versa. The fluids can be either liquids or gases on either the shell or the tube
side. In order to transfer heat efficiently, a large heat transfer area should be
used, leading to the use of many tubes. In this way, waste heat can be put to
use. This is an efficient way to conserve energy.
Heat exchangers with only one phase (liquid or gas) on each side can be
called one-phase or single-phase heat exchangers. Two-phase heat
exchangers can be used to heat a liquid to boil it into a gas (vapor),
sometimes called boilers, or cool a vapor to condense it into a liquid (called
condensers), with the phase change usually occurring on the shell side.
Boilers in steam engine locomotives are typically large, usually cylindrically-
shaped shell-and-tube heat exchangers. In large power plants with steam-
driven turbines, shell-and-tube surface condensers are used to condense the
exhaust steam exiting the turbine into condensate water which is recycled
back to be turned into steam in the steam generator.
Heat Exchanger Phases
Single
Phase
Heat Heat
Exchanger
Exchanger Boiler
Phases
Duo
Phases
Condenser

Condenser Heat Exchanger

Shell And Tube Heat Exchanger Designer
There can be many variations on the shell and tube design. Typically, the
ends of each tube are connected to plenums (sometimes called water boxes)
through holes in tubesheets. The tubes may be straight or bent in the shape
of a U, called U-tubes.

In nuclear power plants called pressurized water reactors, large heat
exchangers called steam generators are two-phase, shell-and-tube heat
exchangers which typically have U-tubes. They are used to boil water
recycled from a surface condenser into steam to drive a turbine to produce
power. Most shell-and-tube heat exchangers are either 1, 2, or 4 pass
designs on the tube side. This refers to the number of times the fluid in the
tubes passes through the fluid in the shell.

Nuclear Two Phase Steam Boiler




In a single pass heat exchanger, the fluid goes in one end of each tube and
out the other.

Two and four pass designs are common because the fluid can enter and exit
on the same side. This makes construction much simpler.
Pas Divider

There are often baffles directing flow through the shell side so the fluid does
not take a short cut through the shell side leaving ineffective low flow volumes.
These are generally attached to the tube bundle rather than the shell in order
that the bundle is still removable for maintenance.
Counter current heat exchangers are most efficient because they allow the
highest log mean temperature difference between the hot and cold streams.
Many companies however do not use two pass heat exchangers with a u-
tube because they can break easily in addition to being more expensive to
build. Often multiple heat exchangers can be used to simulate the counter
current flow of a single large exchanger.

Heat Exchanger Bonnet Forging

Selection Of Tube Material
To be able to transfer heat well, the tube material should have good thermal
conductivity. Because heat is transferred from a hot to a cold side through the
tubes, there is a temperature difference through the width of the tubes.
Because of the tendency of the tube material to thermally expand differently
at various temperatures, thermal stresses occur during operation. This is in
addition to any stress from high pressures from the fluids themselves. The
tube material also should be compatible with both the shell and tube side
fluids for long periods under the operating conditions (temperatures,
pressures, pH, etc.) to minimize deterioration such as corrosion. All of these
requirements call for careful selection of strong, thermally-conductive,
corrosion-resistant, high quality tube materials, typically metals, including
aluminium, copper alloy, stainless steel, carbon steel, non-ferrous copper
alloy, Inconel, nickel, Hastelloy and titanium. Poor choice of tube material
could result in a leak through a tube between the shell and tube sides causing
fluid cross-contamination and possibly loss of pressure.

Applications And Uses
The simple design of a shell and tube heat exchanger makes it an ideal
cooling solution for a wide variety of applications in oil & gas industries.

Tubular Exchanger Manufacturers Association
The Tubular Exchanger Manufacturers Association (also known as TEMA) is
an association of fabricators of shell and tube type heat exchangers. TEMA
has established and maintains a set of construction standards for heat
exchangers, known as the TEMA Standard. TEMA also produces software for
evaluation of flow-induced vibration and of flexible shell elements (expansion
joints). TEMA was founded in 1939, and is based in Tarrytown, New York. The
association meets regularly to revise and update the standards, respond to
inquiries, and discuss topics related to the industry.

Tarrytown, New York

Tarrytown, New York
Lyndhurst Mansion

The TEMA Standard
The current edition of the TEMA Standard is the Ninth Edition, published in
2007. Worldwide, the TEMA Standard is used as the construction standard for
most shell and tube heat exchangers. The standard is composed of ten
sections:
1. Nomenclature
2. Fabrication Tolerances
3. General Fabrication and Performance Information
4. Installation, Operation, and Maintenance
5. Mechanical Standards
6. Flow Induced Vibration
7. Thermal Relations
8. Physical Properties of Fluids
9. General Information
10. Recommended Good Practice

TEMA Exchanger Nomenclature
Because heat exchangers can be configured many different ways, TEMA has
standardized the nomenclature of exchanger types. A letter designation is
used for the front head type, shell type, and rear head type of an exchanger.
For example, a fixed tubesheet exchanger with bolted removable bonnets is
designated as a 'BEM" type. A kettle type reboiler with a removable U-tube
bundle is a 'BKU' type. Many different letter combinations are possible.
'BEM" type 'BKU" type

 BONNET (INTEGRAL COVER)  BONNET (INTEGRAL COVER)
 ONE PASS SHELL  KETTLE TYPE REBOILER
 FIXED TUBESHEET, LIKE 'B' STATIONARY HEAD  U-TUBE BUNDLE

BEM for bonnet type
AEL for channel and
removable cover

Front End Stationary Shell Type Rear End Stationary Head

Head
A: E: L:
CHANNEL ONE PASS SHELL FIXED TUBESHEET,

AND REMOVABLE COVER LIKE 'A' STATIONARY HEAD
B: F: M:
BONNET TWO PASS SHELL FIXED TUBESHEET,

(INTEGRAL COVER) WITH LONGITUDINAL BAFFLE LIKE 'B' STATIONARY HEAD
Charlie Chong/ Fion Zhang http://www.engineeringpage.com/heat_exchangers/tema.html


Head
C: G: N:
CHANNEL INTEGRAL WITH SPLIT FLOW FIXED TUBESHEET,

TUBE- SHEET AND REMOVABLE LIKE 'C' STATIONARY HEAD
COVER Shown: Removable Tube
Bundle only
D: H: P:
SPECIAL HIGH PRESSURE DOUBLE SPLIT FLOW OUTSIDE PACKED FLOATING

CLOSURE HEAD


Head
J: S:
DIVIDED FLOW FLOATING HEAD WITH BACKING

DEVICE
(SPLIT RING)
K: T:
KETTLE TYPE REBOILER PULL THROUGH FLOATING

HEAD


Head
U:
U-TUBE BUNDLE
W:
PACKED FLOATING TUBE

SHEET WITH LANTERN RING

Some examples of the TEMA designation for Heat Exchangers
BEM
Bonnet (Intergral Cover), One Pass Shell, Fixed Tubesheet BonnetFixed
tubesheet heat exchanger. This is a very popular version as the heads can be
removed to clean the inside of the tubes. The front head piping must be
unbolted to allow the removal of the front head, if this is undesired this can be
avoided by applying a type A front head. In that case only the cover needs to
be removed. It is not possible to clean the outside surface of the tubes as
these are inside the fixed part. Chemical cleaning can be used. Shown is a
version with one shell pass and two tube passes.

BEM
This is the same type of heat exchanger as above, but with one tube pass
AEM
Channel with Removable Cover, One Pass Shell, Fixed Tubesheet Bonnet.
This is almost the same type of heat exchanger as the first BEM, the
removable cover allows the inside of the tubes to be inspected and cleaned
without unbolting the piping.

AESChannel and Removable Cover, One Pass Shell, Floating Head with
Backing DeviceFloating Head Heat Exchanger. A floating head is excellent for
applications where the difference in temperature between the hot and cold
fluid causes unacceptable stresses in the axial direction of the shell and tubes.
The floating head can move, i.e. provides the possibility to expand in the axial
direction.
Note that the bundle can not be pulled from the front end. For maintenance
both the front and rear end head, including the backing device, must be
disassembled. If pulling from the front head is required a type AET should be
selected.


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My Reading on Heat Exchanger

Reading 01- An Introduction

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

 In counter-flow heat exchangers the fluids enter the exchanger from

 In a cross-flow heat exchanger,

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang

The U- tube bundle

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Note 1: In science, buckling is a mathematical instability that leads to a failure mode.

Charlie Chong/ Fion Zhang

Note 1: In science, buckling is a mathematical instability that leads to a failure mode.

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

For thermo economic optimization it is suggested

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

Charlie Chong/ Fion Zhang

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Charlie Chong/ Fion Zhang