SRI KRISHNA COLLEGE OF

ENGINEERING AND TECHNOLOGY

(An Autonomous Institution)
(Approved by AICTE and Affiliated to Anna University,
Chennai)
Accredited By NAAC With “A” Grade

INPLANT TRAINNING REPORT

Submitted by

BHUVANNA RAI S (16EUEE023)

In partial fulfillment of the requirements

for the award of the degree
of

BACHELOR OF ENGINEERING
IN
ELECTRICAL AND ELECTRONICS ENGINEERING

SEPTEMBER-2018

i
 ACKNOWLEDGEMENT

We would like to thank the management for supporting us during our

entire inplant training and encouraging us to be innovative and backing us in
everything we did.

We would like to thank our Principal Dr.J. JANET, for allowing us to do

this trainning and providing required time to complete the same.

We express our sincere thanks to our beloved Head of the Department,

Dr. K.LAKSHMI for her encouragement in our endeavor.

ii
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO.

NO.

LIST OF TABLE
LIST OF FIGURES iii
LIST OF SYMBOLS
1 MOTORS
1.1 Drilling 1
1.2 Tapping 1
1.3 Mounting 4
1.4 Threading 5
1.5 Motor casting 6
1.6 Painting 7
1.7 Testing 8
1.8 Packing 11
1.9Types 12

2 COOLANTS
2.1 Shell tube heat exchanger 13
2.2 Fined tube heat exchanger 15
2.3 Testing 17
2.4 Types 18

3 CONCLUSION 20

iii
 LIST OF FIGURES

CHAPTER 1 FIGURE NAME PAGE NO.

1 1.1Threading 6

1.2Painting 8

1.3 Testing 9

1.4 Packing 12

2 2.1 U tube heat exchanger 13

2.2 One pass tube side 14

2.3 Two pass tube side 14

2.4 Finned tube heat exchanger 15

2.5 Tube passes 17

2.6 Testing 18

iv
 CHAPTER 1

MOTORS AND PUMPS

A motor converts electrical energy into mechanical energy. It is estimated that

nearly half of the world's energy consumption is consumed by motors.
Therefore, increasing motor efficiency is expected to have a significant impact
on the global energy crisis.

1.1 DRILLING

The drilling motors from Halliburton Sperry Drilling offer a wide range of
configurations to meet your needs. These motors have the power, torque, and
speed to drill with the most aggressive polycrystalline diamond compact (PDC)
bits for specific down hole conditions or well designs. Using the latest available
technology and materials, the Halliburton motors can be used in an extensive
range of drilling applications, such as:

Vertical, directional, and

Horizontal wells

High temperature

Synthetic-, oil-, and water-based mud systems

Performance drilling

Extended-reach wells

Shale plays

Motor above rotary steerable system – MARSS

1.2 TAPPING

The function of moisture-sealing tapes such as vinyl, rubber, and mastic

products is to exclude moisture from the insulation assembly and provide
electrical insulation. One of these tapes — or alternately a mastic pad —
generally forms the second layer of the insulation assembly. Rubber, mastic,
and filler tapes are also used to pad the underlying surface by covering sharp
edges. With all of the new products and electrical insulation kits currently on
the market, the use of conventional electrical tapes has gone down. As a result,

1
electricians today may not possess the taping skills that once were such an
important part of their predecessors' work. Nevertheless, there is still good
reason to master this craft — especially for those times when repairs are needed
quickly and other products are simply not available.According to Steve
Anderson, a National Joint Apprenticeship and Training Committee (NJATC)
director, the NJATC believes strongly in the importance of splice and
termination taping skills for electricians and linemen. “Taping is the first thing
covered in our cable splice training course, and we spend a lot of time in this
area,” Anderson says. Anderson points out that repair situations can arise in the
field where a splicer does not have access to a particular kit for the job.
However, knowing how to make proper use of tape can save the day, getting the
customer back online quickly. “It's far more economical to complete a job on
the spot with tape than to go in search of a kit,” Anderson maintains.

1.2.1Taping tips

The primary tapes used in electrical applications are vinyl, rubber, mastic, and
varnished cambric. These products have been used in electrical work for many
years, are code approved, and conform to key industry standards, including UL
520, ASTM D1000, and CSA 22.2. The function of moisture-sealing tapes such
as vinyl, rubber, and mastic products is to exclude moisture from the insulation
assembly and provide electrical insulation. One of these tapes — or alternately a
mastic pad — generally forms the second layer of the insulation assembly.
Rubber, mastic, and filler tapes are also used to pad the underlying surface by
covering sharp edges.Rubber tapes are generally non-adhesive, and are either
equipped with a liner or are linerless. Stretched and overlapped layers will fuse
or bond together to form an effective electrical insulation and moisture barrier.
For low-voltage (1000V or less) applications, rubber tapes should be stretched
during wrapping so that tape width is reduced to approximately 75%. For high-
and medium-voltage applications — where the electrical stresses are high (e.g.
connector areas, lug areas, and cable shield cut-back areas) — tape should be
stretched just short of its breaking point.Vinyl tape forms the final outer layer
and serves several important functions in addition to electrical insulation,
including abrasion protection, corrosion resistance, UV resistance, and
protection from chemicals including alkalis and acids. Conformable vinyl tape
is tougher than the softer, stickier surfaces of rubber, mastic, and putty tapes it
protects.Several grades of vinyl electrical tape are available — all of which
differ in conformability, ease of unwinding, resistance of the adhesive to heat
and cold, and loosening (flagging). While general-use vinyl tapes are
2
appropriate for bundling, wire pulling, and other ancillary tasks, premium-grade
vinyl tape is the best choice for permanent insulation work as it handles the
broadest range of environmental factors and functions, such as cold
weather.You should use a minimum of two half-lapped layers of vinyl tape to
insulate and jacket low-voltage components. A half-lap consists of overlaying
each turn by one-half the width of the tape. The general rule of thumb calls for a
tape thickness of 1.5 times the thickness of existing wire or cable insulation. In
every case, tension on the tape should be sufficient to conform the tape evenly
to the surface. A slight reduction in tension is encouraged for the final wrap.
Trim the tape end and allow it to return to shape before pressing down with the
thumb to avoid lifting or flagging.

1.2.2 Tale of the Tape

The first commercial tape for electrical insulation was cotton friction tape,
which became available in the early 1930s. Vinyl electrical tape was introduced
in the mid 40s. This advanced material provided dramatic advantages over
friction tape, including improved adhesion and moisture protection. Vinyl tapes
have been refined substantially over the years, and other tape products have
been added as well. Today's tapes offer long-term performance, excellent
adhesion, and temperature resistance — not to mention smooth unwind from the
roll. Resistance to adhesive transfer, superior conformability, high tensile
strength, good elastic memory and recovery, and wider installation and
operational temperature ranges characterize premium products.

1.2.3 Useful applications

When properly applied, quality tapes can serve as valuable standby resources
for jobs such as insulating motor lead connections, inline splices, and split bolt
and bus bar connections

1.2.4 Motor lead insulation. In the case of low-voltage motor lead connections,
the tape insulating process consists of connecting feeder cables to motor leads
and arranging the conductors for easy wrapping. You should begin by wrapping
two layers of varnished cambric tape, which is available with or without
adhesive. For the adhesive type, apply with the adhesive side out for clean re-
entry.

3
Follow up this first step by wrapping four half-lapped layers of rubber
insulating tape over the cambric tape, which creates a moisture barrier and
provides the primary insulation in the connection. Finally, over-wrap the
assembly with a minimum of two half-lapped layers of vinyl electrical tape.
This should extend approximately two tape widths beyond the ends of the
rubber tape. Stretch this tape as you wrap it so you get good conformance to the
underlying structure. This also helps complete the moisture seal.

Inline splice insulation. You can protect a low-voltage inline splice in a similar
manner by wrapping the installed connector with four half-lapped layers of
rubber mastic tape or rubber splicing tape, and then over-wrapping it with two
half-lapped layers of premium vinyl electrical tape.

Split bolt connection. Protection of a split bolt connection begins with

installing the connector and wrapping it with two layers of varnished cambric
tape. Next, wrap the splice with four half-lapped layers of rubber or rubber
mastic tape. Complete the job by over-wrapping with at least two half-lapped
layers of premium vinyl electrical tape.

Electrical tapes are versatile, suited to a multitude of tasks, and when installed
properly provide a long-term, effective insulation. According to Anderson, both
the NJATC headquarters and local training efforts are strongly supported by
industry suppliers, which provide sample products and assist with course
development and hands-on instruction. In addition, manufacturers of electrical-
grade tapes are generally willing to provide technical support and instruction on
proper taping techniques.

1.3 MOUNTING

Once the motor rating and enclosure type are selected, the mounting style
needs to be determined. Many motors are simply base mounted and close-
coupled or belted to the load. If belted, the pulley sizes and number of belts
need to be reviewed to ensure that the motor bearings are not overloaded.
Coupling a motor to a gearbox is common in the packaging industry. A
NEMA C-face provides a mounting rabbet which engages the gearbox, and
the motor shaft fits into the gearbox. The two components are joined by bolts
through the gearbox threading into the motor face. A D-flange is similar
except the bolts go through holes in the motor flange and into threaded holes
in the gearbox.Machinery built overseas is likely to have motors and

4
 gearboxes conforming to metric IEC standards. Domestic motor
manufacturers offer motors with metric mounting dimensions enabling
replacement with U.S. built motors.

1.4 THREADING

Maintenance crews strive to reduce maintenance costs and manage their

workloads more effectively. Since DC machines require more attention than their
AC counterparts, DC maintenance can help achieve both goals. Time-saving tips
include changing brushes, checking winding insulation with a megohmmeter, and
machining commutators in place. Knowing when to perform this maintenance is
the key.

1.4.1Common commutator wear patterns.

It's relatively easy to judge DC motor performance by looking at the commutator.

During normal commutation, brush current vaporizes some copper molecules,
depositing a uniformly tan to charcoal-brown copper-oxide film (about 2 in.310-
7
in. thick) on the commutator. Faint charcoal streaks along the brush paths may
also indicate normal commutation. Even a heavy film coating isn't necessarily
cause for alarm, particularly if no areas are

Slot bar marking and burning. Alternating dark and light bars on the
commutator can be caused by the first (or last) conductor in the slot passing under
the brush before (or after) entering the field of commutation. Certain factors can
exacerbate slot bar marking and cause slot bar burning including electrical
overload, incorrect neutral setting, improper interpole strength, and contamination.
When the trailing edges of the darker bars appear etched or burnt, you need to
resurface the commutator.

Streaking. Dark streaks along the brush path (often found on motors with long-
life brushes) indicate metal is migrating from the commutator to the brushes.
Insufficient brush spring tension, too light a load, or a brush grade that is too
porous can be responsible. Contamination by chlorine, hydrochloric acid, silicon
vapors, or other harsh chemicals can also cause streaking. Remedying the
contributing factor(s) early on can prevent the condition from progressing to the
more severe stage of threading.

5
Threading. Threading involves the transfer of excessive amounts of metal to the
brushes during commutation when brush path(s) start to resemble the threads on a
bolt As with streaking, threading may be due to inadequate brush spring tension or
too light a load. Left unchecked, the condition will lead to rapid brush wear. If you
detect threading soon enough, you can machine the commutator in place to restore
the finish

Fig. 1.1 Threading

1.5 MOTOR CASTING

The motor casting invention relates to a process for casting motor vehicle
wheels from metal, such as from an aluminum alloy, which wheels have a rim
ring and a hub part connected by supporting radial elements. According to the
present process the casting mold is formed by a plurality of molded core parts
that are mainly ring- and/or disk-shaped and which are axially assembled while
still attached to their mold sections and are centered relative to each other by the
relative adjustment of the mold sections. The parting plane of the core parts runs
perpendicularly to the wheel axis. This permits one-piece wheels to be cast with
great accuracy, which wheels have few, if any, visible mold seams.

1.5.1 Field of the Invention:

The present motor casting invention relates to a process for casting a motor
vehicle wheel and other motor parts from metal, especially from an aluminum

6
alloy, said wheel having a rim ring and a hub part connected thereto by
supporting radial elements. Thus motor casting process is used to manufacturer
different kinds of metal parts of the vehicles which are also called metal casting
or metal castings.

1.5.2 Advantages of Motor Casting:

Because of the special shape of the rim well, motor vehicle wheels cast from an
aluminum alloy are manufactured in such fashion that a bi- or multipartite
radially-openable mold is used for forming the rim well section. However, the
precision that can be achieved in this manner as regards true-running, uniform
wall thickness, etc., make it necessary for the cast blank to be finished by a
costly machining procedure.

All additional elements to be mounted, such as fan rings, trim coverings,

especially trim coverings for purposes of air guidance for example, have to be
manufactured as separate elements and then mounted on the cast wheel body,
such as by bolting. Then, after machining and assembly of the additional parts,
additional finishing is required to balance the finished motor vehicle wheel. Feel
free to contact us to buy or for more information on motor casting, motor
casting process, and motor castings.

1.6 PAINTING
The PFS 3000-2 paint spray system is suited for larger
painting projects using paints, lacquers and glazes on a variety of surfaces.
“Both of these systems require dilution of the liquid to enable easy application.
The PFS 5000-E requires no dilution and is the best solution for large
painting projects.
The paint system has been designed to provide consistent, virtually drip-free
painting.The paint roller is placed in a protective housing, which allows for
a consistent paint finish and minimal dripping. “The paint control
technology guarantees that the user always has the correct amount of paint on the
roller. To increase or decrease the amount of paint being distributed onto the
roller, the user simply has to push a button on the remote control,” he adds.
The PFS 3000-2 paint spray system can be used to spray a variety of water-based
wood glazes, thin-viscosity lacquers, and thick-viscosity wall paints. It features a
650 W motor, requiring minimal dilution of the substance required.
Cameron-Smith highlights that the unit is mobile, as it can be placed on the floor
or hung from the shoulder of the operator using a shoulder strap.

7
The Bosch PFS 5000-E uses a more powerful 1200 W motor, allowing for
undiluted spraying, with good performance and high versatility in its class. There
are also wheels incorporated into the base of the unit for a convenient ‘follow-me’
function for increased mobility.
“The ALLPaint technology of the PFS 3000-2 and the PFS 5000-E enables the
user to spray a variety of materials with various types of paints. The
ConstantFeed system ensures a steady supply of paint, even when being used
overhead or close to the floor,” he points out.

Fig.1.2 Painting

Further, Cameron-Smith says these paint systems can be used for any home
renovation projects. “The PFS 5000-E is ideal for painting the interior and exterior
of houses, including walls, wooden floors and tongue-and-groove panels. “The
PFS 3000-2 can be used for spraying walls, furniture and garden fences. The PPR
250 gets all indoor wall and ceiling painting done with ease

1.7 TESTING
Testing electric motors doesn’t have to be a mystery. Knowledge of the
basics together with powerful new test equipment vastly simplifies the
job.Electric motors have had a reputation for being a mix of science and magic.
So when a motor fails to operate it may not be obvious what the problem is.
Knowing some basic methods and techniques along with having a few test
instruments handy helps detect and diagnose problems with ease When an
electric motor fails to start, runs intermittently or hot, or continually trips its
overcurrent device, there my be a variety of causes. Sometimes the trouble lies
within the power supply, including branch circuit conductors or a motor
controller.

8
 Fig.1.3 Testing

Another possibility is that the driven load is jammed, binding or mismatched. If

the motor itself has developed a fault, the fault may be a burnt wire or
connection, a winding failure including insulation deterioration, or a
deteriorating bearing.A number of diagnostic tools, such as clamp-on ammeters,
temperature sensors, a Megger or oscilloscope, can help illuminate the problem.
Preliminary tests generally are done using the ubiquitous multimeter. This tester
is capable of providing diagnostic information for all kinds of motors.

1.7.1 Electrical measurements

If the motor is completely unresponsive, no ac humming or false starts, take a

voltage reading at the motor terminals. If there is no voltage or reduced voltage,
work back upstream. Take readings at accessible points including disconnects,
the motor controller, any fuses or junction boxes, and so on, back to the over-
current device output at the entrance panel. What you’re looking for is
essentially the same voltage level as measured at the entrance panel main
breaker.
When there is no electrical load, the same voltage should appear at both ends of
the branch circuit conductors. When the circuit electrical load is close to the
circuit capacity, the voltage drop should not exceed 3% for optimum motor
efficiency. In a three-phase hookup, all legs should have substantially equal
voltage readings, with no dropped phase. If these readings vary by a few volts,
it may be possible to equalize them by rolling the connections, taking care not

9
to reverse rotation. The idea is to match supply voltages and load impedances so
as to balance the three legs.

If the electrical supply checks out, examine the motor itself. If possible,
disengage the load. This may restore motor operation. With power disconnected
and locked out, attempt to turn the motor by hand. In all but the largest motors
the shaft should turn freely. If not, there is an obstruction inside or a seized
bearing. Fairly new bearings are prone to seizure because the tolerances are
tighter. This is especially true if there is ambient moisture or the motor has been
unused for a while. Often good operation can be restored by oiling front and
rear bearings without disassembling the motor.

If the shaft turns freely, set the multimeter to its ohms function to check
resistance. The windings (all three in a three-phase motor) should read low but
not zero ohms. The smaller the motor, the higher this reading will be, but it
should not be open. It will usually be low enough (under 30 Ω) for the audible
continuity indicator to sound.

1.7.2 Insulation testing

The insulation resistance tester (or megohmmeter), generally known by its trade
name Megger, can provide critical information regarding the condition of motor
insulation. In an industrial facility, the recommended procedure is to perform
periodic tests and record the results so damaging trends can be detected and
corrected to prevent an outage and extensive downtime.

The insulation resistance tester resembles a conventional ohmmeter. But rather

than the typical three-volt test voltage derived from an internal battery and
present at the probes, the Megger provides a much higher voltage applied for a
proscribed length of time. The leakage current through insulation, expressed as
resistance, is displayed so it can be graphed. This test may take place on
installed or on-the-reel cable, tools, appliances, transformers, power distribution
subsystems, capacitors, motors and any type of electrical equipment or wiring.

The test may be non-destructive, for in-service equipment, or prolonged at

elevated voltage to test prototypes to the point of destruction. A bit of a learning
curve is involved in using the Megger. The correct settings, connection
procedures, test durations and safety precautions must be implemented to avoid
damaging the equipment or electrocuting the operator or coworkers.

The motor under test must be powered down and disconnected from all

10
equipment and wiring that’s not to be included in the test. Besides invalidating
the test, such extraneous equipment could be damaged by the applied voltage.
Additionally, unsuspecting individuals could be exposed to hazardous high
voltages.

All wiring and equipment has an inherent amount of capacitance, which is

generally significant in large motors. Because the equipment is in effect a
storage capacitor, it’s essential that lingering electrical energy be discharged
before and after each test. To do this, shunt the relevant conductor(s) to ground
and to each other before reconnecting the power source. The unit should be
discharged at least four times as long as the test voltage was applied.

The Megger is capable of applying different voltages, and the level should be
coordinated with the type of equipment under test and the scope of the inquiry.
The test generally applies between 100 and 5,000 V or more. A protocol
involving voltage level, time duration, intervals between tests and connection
methods must be composed, taking into account the type and size of the
equipment, its value and role in the production process and other factors.

1.7.3 Motor testing equipment

Newer more contemporary instruments make testing even easier. For instance,
test equipment such as Fluke’s 438-II Power Quality and Motor Analyzer uses
algorithms to analyze not only three-phase power quality but also torque,
efficiency and speed to determine system performance and detect overloaded
conditions, eliminating the need for motor load sensors.

1.8 PACKING

Our range of geared motors for packaging, dynamic weighing and

labelling, with brushless and brush DC motors and high mechanical resistance
gear units. Thanks to our 3 versions of square or tubular flange reducer with up
to 10 reduction ratios and 8Nm output torque, with control options, we're
offering compact and adaptable solutions to the different processes : cutting of
materials, bottling, packaging, labeling, strapping, printing, etc.

11
 Fig.1.4 Packing

Dynamic Weighing: Brushless motor with tubular reducer and integrated speed
control for the conveyor belt, allowing precise control by 0-10Vdc control
signal, start/stop, two programmable fixed speeds and stop with torque holding.
Ideal for meat and food packaging.

Labeling: DC motors with easy-coupled square flange reducer, compact design

and electronic control with possibility of change of direction, running / stop,
speed and current limits and end of stroke. High-speed gearmotor
combinations up to 2,144rpm for high dynamic range applications.

Packaging: Long life brushless motors for continuous and repetitive processes.
Up to 65W in diameter 42mm motor and up to 6.5Nm output torque. Develop
your production line flexibly, with a wide variety of sizes, powers and control
options to improve productivity.The products of the Kelvin range are made up
of high-quality German motors in both brush and brushless DC technology,
coupled with spur gearheads of high-strength carved pinions gear units. Motors
with CE, UL and assembly line with ISO 9001 to comply with health
regulations and safety directives.Benefit from the possibility to provide a
competitive advantage to your fabrications and processes. We can provide a fast
delivery service in 48 hours for the rapid development of prototypes and
preseries.

1.9 TYPES OF MOTORS MANUFACTURED

Electric motors
Buffer motors
Open type motor

12
 CHAPTER 2

COOLANTS

A coolant is a substance, typically liquid or gas that is used to reduce or regulate

the temperature of a system. An ideal coolant has high thermal capacity,
low viscosity, is low-cost, non-toxic, chemically inert and neither causes nor
promotes corrosion of the cooling system. Some applications also require the
coolant to be an electrical insulator.

2.1 Shell tube heat exchangers

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.

Fig.2.1 u-tube heat exchanger

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

13
 Fig2.2 one pass tube side

Surface condensers in power plants are often 1-pass straight-tube heat

exchangers (see surface condenser for diagram). Two and four pass designs are
common because the fluid can enter and exit on the same side. This makes
construction much simpler.

Fig2.3 two pass tube side

There are often baffles directing flow through the shell side so the fluid does not

14
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.
2.1.1 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. Fluoropolymers such
as Perfluoroalkoxy alkane (PFA) and Fluorinated ethylene propylene (FEP) are
also used to produce the tubing material due to their high resistance to extreme
temperatures.[4] 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.
2.2 Finned tube heat exchanger

Fig.2.4 Finned tube heat exchanger

2.2.1Thermal Design Considerations

15
The flow rates of both hot and cold streams, their terminal temperatures and
fluid properties are the primary inputs of thermal design of heat exchangers.
Thermal design considerations Thermal design of a shell and tube heat
exchanger typically includes the determination of heat transfer area, number of
tubes, tube length and diameter, tube layout, number of shell and tube passes,
type of heat exchanger (fixed tube sheet, removable tube bundle etc), tube pitch,
number of baffles, its type and size, shell and tube side pressure drop etc.
2.2.2 Shell
Shell is the container for the shell fluid and the tube bundle is placed inside the
shell. Shell diameter should be selected in such a way to give a close fit of the
tube bundle. The clearance between the tube bundle and inner shell wall
depends on the type of exchanger. Shells are usually fabricated from standard
steel pipe with satisfactory corrosion allowance. The shell thickness of 3/8 inch
for the shell ID of 12-24 inch can be satisfactorily used up to 300 psi of
operating pressure.
2.2. Tube
Tube OD of ¾ and 1‟‟ are very common to design a compact heat exchanger.
The most efficient condition for heat transfer is to have the maximum number
of tubes in the shell to increase turbulence. The tube thickness should be enough
to withstand the internal pressure along with the adequate corrosion allowance.
The tube thickness is expressed in terms of BWG (Birmingham Wire Gauge)
and true outside diameter (OD). The tube length of 6, 8, 12, 16, 20 and 24 ft are
preferably used. Longer tube reduces shell diameter at the expense of higher
shell pressure drop. Finned tubes are also used when fluid with low heat transfer
coefficient flows in the shell side. Stainless steel, admiralty brass, copper,
bronze and alloys of copper-nickel are the commonly used tube materials

Tube pitch, tube-layout and tube-count

Tube pitch is the shortest centre to centre distance between the adjacent tubes.
The tubes are generally placed in square or triangular patterns (pitch). The
number of tubes that can be accommodated in a given shell ID is called tube
count. The tube count depends on the factors like shell ID, OD of tube, tube
pitch, tube layout, number of tube passes, type of heat exchanger and design
pressure.

Tube passes

16
 Fig.2.5 tube passes

The number of passes is chosen to get the required tube side fluid velocity to
obtain greater heat transfer co-efficient and also to reduce scale formation. The
tube passes vary from 1 to 16. The tube passes of 1, 2 and 4 are common in
application. The partition built into exchanger head known as partition plate
(also called pass partition) is used to direct the tube side flow.

Tube sheet

The tubes are fixed with tube sheet that form the barrier between the tube and
shell fluids. The tubes can be fixed with the tube sheet using ferrule and a soft
metal packing ring. The tubes are attached to tube sheet with two or more
grooves in the tube sheet wall by „tube rolling‟. The tube metal is forced to
move into the grooves forming an excellent tight seal. This is the most common
type of fixing arrangement in large industrial exchangers. The tube sheet
thickness should be greater than the tube outside diameter to make a good seal.
The recommended standards (IS:4503 or TEMA) should be followed to select
the minimum tube sheet thickness.

2.3 Testing
Examination and condition monitoring of heat exchangers are performed using
a variety of techniques. Selection of the best technique for you depends on your
objectives: whether it is fabrication control, preventive in-service inspection, or
inspection due to a failure such as a leakage.
An essential part of our solution is testing services with non-destructive (NDT)
methods. For example, unnecessary process downtime, change-out costs and
pressure testing can be avoided with these services. Kiwa Inspecta offers you
methods such as IRIS and eddy current testing, which provide high-speed
results in finding defects that threaten the safe usage of your heat exchanger

17
 tubing.
According to each customers’ needs, we carry out product development and
plan the best ways to execute inspections and modernization upgrades.
Carefully mapping the important areas and critical components, we aim at
ensuring good usability and minimal interruptions in your production.

Fig2.6 testing
uses the latest methods and techniques for your benefit so that you can plan
ahead, have inspections when it is best for you, carry out upgrades cost
efficiently and use your equipment safely for the next usage period, after which
a new assessment can be made. Most advantages can be gained in close co-
operation with our inspectors, technical consultants and you, the customer.
Together we can e.g. produce preventive and risk-based maintenance and
inspection plans for the future.
Benefits of Testing of Heat Exchangers

• Detects wearing, corrosion and other damages easily

• Prevents leakages, accidents etc. that are harmful to health and environment
• Helps you do the right maintenance action at the right time
• Saves you costs, maximizes process uptime
• Enables you to keep your heat transfer capability at the designed level

Types of Heat Exchangers manufacture

• Shell and Tube Heat Exchanger

• Plate Heat Exchanger

18
• Regenerative Heat Exchanger

• Adiabatic Wheel Heat Exchanger

19
 CHAPTER 3

CONCLUSION

Thus the inplant training in Suguna motors and pumps provided

knowledge about the various process involved in the manufacturing of an
electric motor and the various types of motors manufactured and also the in
plant training in SS heat Recovery India’s private limited provided knowledge
about the various types of coolants used to recover heat , the process involved in
manufacturing it and the types coolants manufactured.

20