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3 Days session at IIT Gandhinagar, Gujarat on

Pressure Vessel

By
- Prakash B Thakur
(Chief Engineer Mechanical, Uhde India Pvt Ltd)
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
1

Uhde India

About the Speaker


Faculty

Prakash B. Thakur, Chief Engineer Mechanical,

Qualification

Diploma in Mechanical Engineering (DME) from Mumbai Univ., 1994


Bachelor of Engineering, Mechanical (BE Mech.) from Mumbai Univ.1998

Experience

1 yr hands on experience in shop maintenance in 1994-95


11 yrs with major Engineering consultant like Technip, Petrofac, Uhde as
Pressure Vessel Engineer.
2 yrs as Project Manager (Engineering) with John Zink India.
Worked with Uhde India from 1998-03 and re-joined in 2008.

Have been handling Chemical / Petrochemical project (Ammonia Urea fertilizer, LAB, SB Rubber etc)
and Refinery projects for well known national and international clients in the position of Lead Pressure
Vessel Engineer. Have been deputed to Europe, Middle east region on official assignments several
times.

Contact Detail
Prakash B. Thakur,
Uhde India Pvt. Ltd,
Uhde House, LBS Road, Vikhroli (W), Mumbai -400083
Email: Prakash.Thakur@Thyssenkrupp.com
DID : +91-22-6704 6641
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
2

Uhde India

Todays session?

Pressure Vessels
Basics
Components of Pressure Vessels,
Shell & Dish
Internal & External Pressure
Nozzle, Reinforcement & Manhole
Vessel Supports
Ladders & Platforms
Safety Devices
Vessels Internals

Reactors
Process Column
Heat Exchangers

Day 1

Day 2 Material Strength, Codes, different loads, design and some examples etc.
Day 3 Material Selection, Testing, special requirements, costing etc.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
3

Uhde India

Static Equipments in Industry


Pressure Vessels

Drums / Vessels

Process Columns / Towers,

Heat Exchangers,

Heaters,

Spheres,

Storage Tanks,

Silos etc

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
4

Uhde India

Petrochemical Plant

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
5

Uhde India

3D Modeling of plant in Uhde

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
6

Uhde India

What is a pressure vessel?


Definition: A pressure vessel, in a simplest form, is
any container that has pressure that is different
than atmospheric pressure. A container with a
vacuum inside is also a pressure vessel.

The most practical examples of pressure vessels is domestic Pressure cooker. Even a carbonated
soda/soft drink bottle is a pressure vessel.

Industrial examples are KO Drum, Surge Drums, Pots, Separators, Process Columns, Shell & Tube
heat exchangers etc.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
7

Uhde India

Pressure vessel types?


Thinned wall - Ratio (Thk / Dia.) < 0.1
Another way of saying this is a pressure vessel is thinned walled if the diameter is 10 times more
than thickness. These pressure vessels are the most common. The stress across the thickness is
assumed to be uniform. No bending stresses but only membrane stress. Entire analysis is based on
maximum stress theory.
Thick wall -Ratio (Thk / Dia.) > 0.1
These pressure vessels are the least common. The stress across the thickness is not uniform.
Special design approach is required for thick wall vessels. The analysis is based on maximum shear
stress theory.
Storage tanks - Storage tanks are a category of thin walled pressure vessels except that are
typically under 15-psi and are super thin when compared to the ratio above. These are basically
meant for storage of fluid.
Transportable Containers - These are the most common pressure vessel and potentially the most
ignored. LPG tankers, chemical tankers seen on the roads are some of the examples.
Gas cylinders CO2, O2, Helium gas cylinder etc used in hospitals, welding machines etc are
examples.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
8

Uhde India

Components of Pressure Vessels


Major components of Pressure vessels are,
1. Shell
2. Heads
3. Nozzles, Manholes
4. Supports
5. Safety Devices
6. Internals
7. Ladder, platforms etc.
8. Other attachments like lifting lugs, support clips etc.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
9

Uhde India

Component Shell & Head


Pressure vessel can be of any shape. Most
common form of pressure vessel is cylindrical shell
with dished end.
Rectangular / Square shape is not used due to
higher thickness required (pure bending stress
case).
Cylindrical shell & dished head subjected to
membrane stresses & not direct bending stress and
hence thickness is less.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
10

Uhde India

Membrane Stress?
For thin wall vessels, when the thickness is small in
comparison with other dimensions vessel wall is referred
to as membrane and the associated stresses resulting
from the contained pressure are called membrane stress.
A membrane stress implies a stress equal over a surface
resulting from loading. These membrane stresses are
average tension or compression stresses. Often, the
loading that can impose a stress in this manner is a
uniformly distributed load like internal pressure.
These are assumed to be uniform across the vessel wall
and act tangentially to its surface. The membrane or wall
is assumed to offer no resistance to bending.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
11

Uhde India

Types of Heads

Though spherical shape is most preferred shape due higher holding capacity & minimum
thickness requirement but it is not so common due fabrication difficulty and associated cost.
Spherical vessels are used only in high pressure application (like reactors) or where high volume
is to be stored (spherical tanks).

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
12

Uhde India

Conical / Toriconical Transition

Angle of cone shall be as per ASME.


Tori-cone shall be used when loads/Pressure is higher or larger angle is required to be used.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
13

Uhde India

Internal Pressure Stresses


A pressure vessel has to retain to pressure. In doing this the pressure applies two types of
stresses in a pressure vessel. They are circumferential and longitudinal.
Basic formula for pressure vessels Stress in
longitudinal direction = P x R/ 2 x t
Stress in Circumferential direction = P x R /t
Where, R = Mean radius & t = Thickness
What is important to remember is longitudinal stresses
are

half

stresses.

as

much

as

the

circumferential

Therefore, broadly we can say that,

longitudinal strength of vessels is twice as strong as


circumferential strength.
Above is just a basic formula and the actual formulae
are given in design code which takes into account of
weld joint efficiency etc. Refer table in the next slide
for exact code formulae for thickness calculations.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
14

Uhde India

ASME Code formulae for thickness calculations

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
15

Uhde India

ASME Code formulae for thickness calculations


Legends,
P = Internal design pressure,
r = Corroded internal radius. Add corrosion allowance in internal radius,
S = Allowable Stress. When used in the thickness calculation equations, this is the allowable stress
for the material used,
E = Longitudinal weld joint efficiency
tp = Required wall thickness for internal pressure of the part under consideration,
t = Actual wall thickness (less corrosion allowance) of the part under consideration,
D = Inside diameter, in. Add twice the corrosion allowance to specified uncorroded inside diameter.
DL = Cone inside diameter at large end, in. Add twice the corrosion allowance to specified
uncorroded inside diameter.
DS = Cone inside diameter at small end, in. Add twice the corrosion allowance to specified
uncorroded inside diameter.
L = Inside crown radius of tori-spherical head, in. Add corrosion allowance to specified uncorroded
inside crown radius.
= One half of the apex angle of the cone at the centerline in degrees .

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
16

Uhde India

External Pressure Stresses


Pressure vessels are subject to compressive
forces due to internal vacuum. Effect of
compressive stress is different for vessel
component then internal pressure. This
difference in behavior is due to elastic
instability, which makes shells weaker in
compression than in tension. In failure by
elastic instability, the vessel is said to
collapse or buckle.
Increasing the thickness or adding stiffener
rings helps is avoiding collapsing / buckling
due to external pressure.

Failure due to vacuum pressure


Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
17

Uhde India

Vessel Thickness
Thus we can broadly conclude that the vessel thickness is basically a function of,

Material (i.e. allowable stresses),

Diameter,

Pressure (int. / ext.),

Temperature,

Unstiffened length (external pressure),

Any other external loads (Wind / seismic /)

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
18

Uhde India

Component - Nozzles Connections & Manholes


A nozzle is a cylindrical component that penetrates the shell or heads of a pressure vessel. The
nozzle ends are usually flanged to allow for the necessary connections and to permit easy
dismantling for maintenance or access. Nozzles are used for the following applications:
1. Attach piping for flow into or out of the vessel.
2. Attach instrument connections, (e.g., level gauges, thermo wells, or pressure gauges).
3. Provide access to the vessel interior through man ways.
4. Provide for direct attachment of other equipment items, (e.g., a heat exchanger or mixer).
Holes are puncture in the vessel wall for attaching the nozzle pipe. A volume of material is removed
from the pressure vessel & this metal is no longer available to absorb the applied loads. This means
local weakening of the vessels takes place due to material removal and hence additional local
reinforcement is provided in the form of Reinforcement Pad or Self Reinforcing nozzle (thicker
pipe/hub).
In a simplified way, material used to replace the area removed for nozzle must be equivalent in metal
area & must be adjacent to opening.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
19

Uhde India

Nozzle Reinforcement - Basics

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
20

Uhde India

Nozzle - Manhole & Davit


Manholes are generally 20 or 24 nozzle with cover provided
on pressure vessel for accessing vessel internals for inspection
during commissioning or shutdown. Size of manhole is large
enough to allow average person to enter inside the vessel.
Davit cover acts as hinge system for manhole for ease of
opening/closing by single person and use of crane for lifting
heavy cover.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
21

Uhde India

Component - Supports
Support are important component of pressure. Needs to
be selected wisely. Supports are to be design to support
the pressure vessel under different loads conditions.
For tall process column, heavy reactors etc. support
design is next most interesting thing to design after
pressure vessel wall.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
22

Uhde India

Component - Supports
The main type of supports for Vertical vessels are,
1. Leg Support
2. Bracket / Lug Support,
3. Skirt Support and,
4. Saddle supports are the most common type of support for Horizontal Vessels.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
23

Uhde India

Component, Supports - Leg


One of the most simplest method of supporting. Used normally
for small size vessel when there is no dynamic loads.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
24

Uhde India

Component, Supports Legs for large Sphere

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
25

Uhde India

Component, Supports - Bracket / Lug


This type of supporting is used for vertical vessel when
resting on platform level. Different configurations
possible based on loads and size.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
26

Uhde India

Component, Supports - Skirt


Most popular type support for vertical vessel under moderate / heavy loads. Process columns are
most of the time supported by skirt support.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
27

Uhde India

Component, Supports - Saddle


Saddle supports - Two numbers (Fixed & Sliding) to take care of thermal expansion of the vessel along
length. Some time more than two supports are also used (**).

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
28

Uhde India

Component - Ladder & Platform


Ladder and platforms are provided to access manhole during
plant shutdown or access the valves, instrument nozzles for
taking reading, sample collection during plant in operation etc.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
29

Uhde India

Component Safety Devices


There are different types of over pressurization devices. These are necessarily safety devices meant
for keeping vessel pressure within design pressure.
Relief Valves - Relief valves open at a set pressure and re-close at the same pressure. These
devices are suitable for liquid service.
Safety Valves - Safety valves are strictly for vapor or gas service. The vapor or gas should be
relatively clean to ensure continued and successful operation. A typical vapor is steam, an example
for gas would be compressed air. These are not meant for liquids. These valves pop open at a set
pressure and reset at a lower pressure called blow down.
Safety Relief Valves - These are meant to handle fluid streams that have liquids and vapor. These
valves pop open at a set pressure and reset at a lower pressure (very much like a safety valve).
Rupture disk - Rupture disks are probably the most versatile over- pressurization device. These can
only be used once. They are the only device that can be used in conjunction with other overpressurization devices.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
30

Uhde India

Component - Vessel internals


1. Trays
2. Packing
3. Demister (Mist Eliminator)
4. Inlet distributors
5. Dip pipes,
6. Vortex breaker
7. Outlet Collector
8. Packing support / hold down grids
9. Many others

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
31

Uhde India

Reactors

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
32

Uhde India

Reactors
Reactors are nothing but pressure vessels. The process fluid
undergoes a chemical reaction inside a reactor. This reaction
is normally facilitated by the presence of catalyst which is held
in one or more catalyst beds.
Generally, pressure & temperature involved in the reactors
are very high. The presence of high temperature & pressure
results in higher wall thickness (even up to 400mm), very
heavy weight and special fabrication/welding techniques. The
material selection (for high temp, special service) is most
important in Reactors.
Depending on thickness and diameters, reactor shell / dish
can be either rolled plates or forgings.
Internals like pre-distributor, distributor, outlet collectors etc.
are supplied by the highly qualified companies.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
33

Uhde India

Types of Reactors
Tubular Reactors & Large Heat Exchangers : This Reactor is used in ethylene oxide, methanol and
MTBE production plants. These exchangers containing several thousand tubes, are typically used in
low and medium pressure processes. Tubular Reactors consist of large shell & tube heat exchangers
with very large diameters (up to 8 m) and over 10,000 tubes. Each tube is welded to the tube sheets
with special welding technology for conventional and high alloy materials. Key factors for tubular
reactor manufacturing are tube sheet drilling technology with reduced tolerances and tube to tube
sheet welding operations.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
34

Uhde India

Specialized welding
Technique used for
Reactor welding

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
35

Uhde India

Process Columns

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
36

Uhde India

Process Columns
Columns or Tower are also pressure vessels in which heat & mass
transfer takes place with help of trays, packing and other internals. Gas
and liquid flows in opposite direction to induce mass &/or heat transfer.
E.g. Distillation, Absorption, Desorption, Splitter column etc.
Due to considerable height of column, ladder and platforms are always
provided on column on regular intervals.
A tower typically contains internal trays &/or packing in the cylindrical shell
section.
These internal trays are needed for flow distribution. Several types of
tower trays are available, such as the bubble -cap, valve, sieve, with
single / double / triple pass and so on. The particular type of tray used
depends on the specific design conditions and process application.
Following internals are generally present in a process column.
Trays & Down comers,
Feed distributors
Packing & support grids, support beams
Seal Pan / Collector tray
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
37

Uhde India

Column Size
Process column size is generally large, creates problem of transportation & erection at site.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
38

Uhde India

Column Size

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
39

Uhde India

Column Size

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
40

Uhde India

Trays & Down comers

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
41

Uhde India

Types of Trays
There are many types of tray designs for different
application

based

on

hydraulics

&

performance

guarantee parameters. There are many proprietary


designs by each tray manufacturer depending the
applications. The most common & conventional ones
are:
Bubble cap trays - A bubble cap tray has riser or
chimney fitted over each hole, and a cap that covers the
riser. The cap is mounted so that there is a space
between riser and cap to allow the passage of vapour.
Vapour rises through the chimney and is directed
downward by the cap, finally discharging through slots in
the cap, and finally bubbling through the liquid on the
tray.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
42

Uhde India

Valve Trays
Valve trays
In valve trays, perforations are covered by liftable
caps. Vapour flows lifts the caps, thus self creating
a flow area for the passage of vapour. The lifting
cap directs the vapour to flow horizontally into the
liquid, thus providing better mixing than is possible
in sieve trays.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
43

Uhde India

Sieve Trays
Sieve trays
Sieve trays are simply metal plates with holes in
them. Vapor passes straight upward through the
liquid on the plate.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
44

Uhde India

Type of Tray Down-comers

Single pass tray


CROSS FLOW

Double pass tray


SPLIT FLOW

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
45

Uhde India

Process Columns
Cross section

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
46

Uhde India

Packed Column
There is a trend to improve separations by supplementing the use of trays by additions of packings.
Packings are passive devices that are designed to increase the interfacial area for vapor-liquid
contact.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
47

Uhde India

Packing
Packings impart good vapor-liquid contact when
placed

together

in

numbers,

without

causing

excessive pressure drop. High pressure drop would


mean more energy is required to drive the vapor up
the distillation column.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
48

Uhde India

Inlet distributors/Pre-Distributors / re-Distributors


Liquid distributors are used above each bed of packing in a packed column to provide uniform liquid
distribution. The distributor, depending on its design features, is generally located 6 to 8 in.
[150 to 200 mm] above the packing. The distributor type determines vertical spacing and the proper
distance needed to disengage the vapor phase from the packing before the vapor passes through the
distributor gas passage area.
An ideal distributor shall have following attributes, each providing a specific effect on the overall
performance of the packed tower:
Uniform liquid distribution
Resistance to plugging or fouling
Wide operating range
Low vapor phase pressure drop
Minimal use of vessel height
Strength for long life without sagging

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
49

Uhde India

Packing versus Trays


1. Packing provide extra inter-facial area for liquid-vapor contact.
2. Efficiency of separation is increased for the same column height.
3. Packed columns are shorter than trayed columns.
4. Packed columns are called continuous-contact columns while trayed columns are called stagedcontact columns.

Column internals are special components of Process column. Whole performance of the
column depends upon correct process design and usage of right internals.
These internals are supplied by reputed vendors after details design & hydraulics of column to
suit the application.
Koch Glitch, Sulzer, Kevin etc are some of the major players in the field of Column internals.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
50

Uhde India

Heat Exchangers

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
51

Uhde India

Heat Exchangers
In most of the plants fluids are heated or cooled using heat exchangers. A heat exchanger is a
specialized device that assists in the transfer of heat from one fluid to the other. A solid wall may
separate the fluids to prevent them from mixing.
Common appliances containing a heat exchanger include air conditioners, refrigerators and space
heaters.

Commonly used heat exchangers in the industry


1. Plate heat Exchangers Used incase of large area requirements. High cost involved.
2. Air coolers Large flow rate of air can be utilized, high initial cost, more maintenance & fouling
due to dirt etc.
3. Shell and Tube heat exchanger Traditional yet most popular type of exchanger used, will be
discussed in little more detail. Most robust type & versatile.
4. Special type Spiral, Twisted tube etc

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
52

Uhde India

Plate Heat Exchanger (PHE)


The basic plate heat exchanger consists of a series of thin, corrugated plates (0.6mm to 1.00mm
thk) that are gasketted or welded together depending on the liquids passing through and dismantling
requirements. The plates are compressed together in a rigid frame to create an arrangement of
parallel flow channels. One fluid travels in the odd numbered channels, the other in the even.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
53

Uhde India

Plate Heat Exchanger (PHE)

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
54

Uhde India

Air Cooler
It is quite common, these days, for Air cooled heat exchangers to handle more than half the heat
dissipation load in a refinery or petrochemical plant.
Air is being used as cooling medium which is available freely.
Advantages are,
1. The heat exchangers can be located at any point within a refinery, thus eliminating long
pipe runs for either the process fluid or the cooling water.
2. Scale buildup on the cooling water side of a shell-and-tube heat exchanger is eliminated,
as well as the related shutdowns for cleaning.
3. Cooling tower water treatment and disposal of resulting waste water is eliminated.
4. The overall cost of dissipating heat by this means is generally less than by other methods
for fluid streams above 66C.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
55

Uhde India

Air Cooler

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
56

Uhde India

Types of Air Coolers

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
57

Uhde India

Types of Air Coolers


Forced Draft

Induced Draft

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
58

Uhde India

Shell & Tube Heat Exchangers (STHE)


The shell & Tube heat exchanger is essentially a Pressure vessel with compartment wall separating
two fluids.
Two compartment of pressure vessels are called Shell side & Tube (channel) side.
Components of STHE,
Shell,
Shell cover,
Tubes,
Channel,
Channel cover,
Tube sheet,
Baffles,
Nozzles
Other components include tie-rods and spacers, pass partition plates, impingement plate,
longitudinal baffle, sealing strips, supports etc.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
59

Uhde India

Basic construction of STHE

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
60

Uhde India

Basic construction of STHE

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
61

Uhde India

About the TEMA code


The pressure parts of a shell-and-tube heat exchanger are designed in accordance with a pressure
vessel design code such as ASME, BSS 5500, A. D. Merkblatter, and so on, but a pressure vessel
design code alone cannot be expected to deal with all the special features of shell-and-tube heat
exchangers. To give guidance and protection to designers, fabricators, and purchasers alike, a
supplementary code is desirable that provides minimum standards for design, materials,
thicknesses, corrosion allowances, fabrication, tolerances, testing, inspection, installation,
operation, maintenance, and guarantees for shell-and-tube heat exchangers.
One universally accepted code that does this is the Standards of Tubular Exchanger Manufacturers
Association, known as TEMA. Although TEMA is designed specifically to supplement the ASME
Boiler and Pressure Vessel Code, Section VIII, Division 1, a large portion of it may be used to
supplement other pressure vessel codes if required.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
62

Uhde India

TEMA Types
TEMA designations for
shell-and-tube heat
exchangers.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
63

Uhde India

When to use which type of Exchanger


1. Type U, U-Tube Exchangers: These units are constructed using U shape tubes that are
attached to the same tube sheet. This design may be used with A, B, C, N, or D type front end.
Advantages:
1. Tube bundle is removable, therefore
mechanical cleaning is possible on the shell
side.
2. Attachment of tubes to single tube sheet
eliminates the need for differential expansion
joint.
3. This type is suitable for high pressure.
4. High degree of protection from leakage is
possible.
5. Double tube sheet is possible to provide
further protection from leakage.

Limitations:
1. Only chemical tube side cleaning is possible.
2. Access to the tubes other that the outside row is
limited.

For the above reason, this type is recommended for clean process fluids and those subject to
chemical cleaning.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
64

Uhde India

Kettle type Exchanger with U-bundle

Vapor space in the form of kettle. Condensing/Evaporation application


Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
65

Uhde India

U Bundle

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
66

Uhde India

When to use which type of Exchanger


2. Type L, M, and N Fixed tube sheets: These units are constructed with the tube sheets
integral with the shell. They may be used with A, B, or N Type front head.
Advantages:
1. High degree of protection against
contamination of streams.
2. Double tube sheet is possible.
3. Mechanical tube side cleaning is possible.

Limitations:
1. Differential expansion is possible only by
using expansion joint.
2. Tube bundle is not removable.
3. Shell side mechanical cleaning is not possible.

These types are recommended for low and high pressure, but low fouling fluids and where
leakages are to be avoided.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
67

Uhde India

Fixed tube sheets

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
68

Uhde India

When to use which type of Exchanger


3. Type S Inside split backing ring Floating head: The floating tube sheet is sealed to a
floating head cover using a split backing ring and a gasketted surface.
Advantages:
Limitations:
1. Higher pressure is possible.
1. Failure of gasket is not externally visible,
2. Differential expansion is provided by the
therefore internal leakage might go undetected
for sometime.
floating head.
3. Shell and tube mechanical cleaning is
possible.
4. Tube bundle is removable.

The above type is recommended for high pressure, non-hazardous process fluids.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
69

Uhde India

When to use which type of Exchanger


4. Type W Packed Lantern Ring Floating Head: The shell side and tube side streams are
individually sealed by individual packing and are separated by a lantern ring. This is the lowest
cost of the floating head designs and can be used with type A, B, or C front head.
Advantages:
1. Differential expansion between tubes is
possible thru the floating head design,
therefore eliminates the need for an expansion
joint.
2. Tube bundle is removable. (Also individual
tubes)
3. Tube side mechanical cleaning is possible.
4. Shell side mechanical cleaning is possible.

Limitations:
1. Maximum of only two tube side passes is
possible.
2. The shell and tube side leakage is possible.
3. Maximum temperatures of 200 C and
maximum pressure of 20 Kg/cm2g limits the
usage of these units at higher pressure and
temperature.

This type is recommended for low pressure,


low temperature and non-hazardous fluids.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
70

Uhde India

When to use which type of Exchanger


5. Type P Outside packed floating head: A skirt attached to the floating tube sheet passes
through the back end of the shell. The space between the skirt and the shell is sealed by several
layers of packing and packing gland.
Advantages:
1. High pressure on tube side is possible.
2. Tube bundle is removable. (Also individual
tubes)
3. Shell and tube mechanical cleaning is
possible.
4. More than two tube passes is possible to
utilize the allowable pressure drop.
5. Packing failure is externally visible under
operation.
7. Differential expansion is provided by the
packing.

Limitations:
1. Hazardous material should not be used on the
shell side because of the possible leakage.
2. Packing will tend to limit shell fluids to
temperatures below 300 F and
pressure below 150 psi.

This types are recommended for low pressure, low temperature non-hazardous fluids.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
71

Uhde India

When to use which type of Exchanger


6. Type T pull through floating heads: The floating tube sheet is designed with a larger
diameter than required for the tube array.
Advantages:
1. Tube bundle is removable. (Also individual
tubes)
2. Differential expansion is provided by the
floating head.
3. Shell and tube side mechanical cleaning is
possible.
4. Double tube sheets are possible.

Limitations:
1. The seal is not externally visible; therefore
leakage might be undetected for some time.
2. This type will tend to be more expensive than
other types.

This types are recommended for low pressure, low temperature non-hazardous fluids.

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
72

Uhde India

Summary of Features

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
73

Uhde India

Fluid allocation basics

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
74

Uhde India

Types of Baffle

Tube Pitch

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
75

Uhde India

Sectional Model of STHE

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
76

Uhde India

Tube to Tube sheet joint in STHE


a) Strength Welded
b) Expanded & seal welded
c) Rolled expanded in grooves
d) Expanded only

a)

b)

c)

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
77

Uhde India

Helical Baffle STHE

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
78

Uhde India

Twisted Tube STHE

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
79

Uhde India

Other Exchanger Type


a) Double pipe Exchanger
b) Spiral Heat Exchanger
c) Corrugated tube exchanger

Double Pipe

Corrugated Tube

Spiral plate flow principle

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
80

Uhde India

End of Session Day1


Thank You

Title Basics of Pressure Vessel


Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
81

Uhde India

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