Heat Exchangers

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Table of Contents
1. Use of Exchangers
2. Types of Exchangers
3. Types of Shell and Tube Exchangers
4. Layout of Shell and Tube Exchangers in
Banks
5. Alterations That Can Be Made to Shell and
Tube Exchangers
6. Establishing Elevations of Exchangers
7. Piping
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Use of Exchangers
Heat exchangers transfer heat from one media to another. In the
petrochemical industry, they can be generally classified under the following
headings:

 Exchanger: Heats one stream and cools the other. There is no heat loss
and physical change in either flowing media.

 Cooler: Cools liquid or gases without condensation; applies also to

intercooler and aftercooler.

 Condenser: Condenses vapour or vapour mixture. Can be water - cooled

or by sufficiently cold process stream which requires heating.

 Chiller: Uses refrigerant for cooling process stream below freezing point or
bellow prevailing cooling water temperature.

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 Heater (non fired) Heats process stream generally up to its boiling point
without appreciable vaporization. Heating medium is usually steam; applies
also to preheaters.
 Reboiler: Reboils the bottom stream of tower for the fractionation process.
Heating medium can be steam or hot process stream. When large quantities
of vapor have to be produced the kettle type reboiler is used.
 Waste heat boiler: Uses waste heat, such as internal combustion exhaust
from gas turbines or similar drivers for steam generation.
 Steam generator: Uses heat of process liquid or gas for producing steam.
 Vapourizer: Vapourizes part of a process liquid stream as does an
evaporator.

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2. Types of Exchangers
Briefly, exchangers, etc. , can be divided into the following three groups :
 Shell and tube:
Which can be vertical or horizontal with the horizontal ones single or
stacked in multi-units. As the name suggests, they consist of a
cylindrical shell with a nest of tubes inside.

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The Shell and Tube (u-tube) is the most common type of heat exchanger
used in the process, petroleum, chemical and HVAC industries, it
contains a number of parallel utubes inside a shell. Shell Tube heat
exchangers are used when a process requires large amounts of fluid to
be heated or cooled. Due to their design, shell tube heat exchangers
offer a large heat transfer area and provide high heat transfer efficiency.
There are many different types or designs of shell and tube heat
exchangers to meet various process requirements. Shell and Tube heat
exchangers can provide steady heat transfer by utilizing multiple passes
of one or both fluids. SEC shell and tube heat exchangers come in two

(2) and four (4) pass models standard, and multi-pass custom models .

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 Fin tube:
This consist of a finned tube through which passes one media jacketed
by another tube through which passes the other media. They can be
used as single or multi - units.
Finned Tube Heat Exchanger

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 Air fins:
Come in two shapes ; flat box units and “a” frame units. Both consist of
banks of finned tubes through which passes the media to be cooled.
Large fans blow air from atmosphere through the banks, thus cooling
the flowing media. There are other types, such as plate exchangers,
carbon block exchanger, etc., but these are used infrequently.

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3. Types of Shell and Tube Exchangers
 Floating head exchangers
Floating head exchangers are used when the media being handled
causes fairly rapid fouling, and the temperature creates expansion
problems. Tubes can expand freely ; channel head and shell cover
arrangement is convenient for inspection, and the tube bundle can
easily be removed for cleaning.

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 U-tube exchangers
U-tube exchangers are used when fouling of the tubes on the inside is
unlikely. The tubes are free to expand and the bundle can be removed
from the shell for cleaning on the shell side of tubes.

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 Fixed head exchangers
Fixed head exchangers have no provision for the tube expansion and
unless a shell expansion joint is provided can only be used for relatively
low temperature service.
The end covers are removable so that the inside of the tubes can be
cleaned by rodding or other similar tools. This type of cleaning is
usually carried out in situ so some space should be allowed in the
piping layout to allow for this.

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 The Shell and Tube recuperative type of heat exchanger which is the most
common in practice may be designed according to one of the following
types:

1) Parallel-flow

2) Counter-flow

3) Cross-flow

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 Parallel-flow Heat Exchanger
Figure below shows a fluid flowing through a pipe and exchanges heat with
another fluid through an annulus surrounding the pipe. In a parallel-flow heat
exchanger fluids flow in the same direction. If the specific heat capacity of
fluids are constant, it can be shown that:

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 Counter-flow Heat Exchanger

Figure above shows a fluid flowing through a pipe and exchanges heat
with another fluid through an annulus surrounding the pipe. In a
counter-flow heat exchanger fluids flow in the opposite direction. If the
specific heat capacity of fluids are constant, it can be shown that:
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 Cross-flow Heat Exchanger

In a cross-flow heat exchanger the direction of fluids are prependicular

to each other. The required surface area, Across for this heat exchanger
is usually calculated by using tables. It is between the required surface
area for counter-flow, Acounter and parallel-flow, Aparallel i.e.

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4. Layout of Shell and Tube Exchangers in Banks

For good maintenance and safe working conditions, it is necessary to

space exchangers such that surrounding area is adequate and clear.

They may be spaced apart and grouped in pairs. When apart, a clear
access way of 750 mm is considered adequate, this being the clear
space between the shells and/or the associated pipework and
insulation. For paired exchangers a similar condition is required
between pairs and adjacent singles, but between each shell of the pair
this may be reduced to 450 mm between head flanges.

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Exchangers should always be arranged such that the ideally there is a
minimum of 150 mm clear at the rear for removal of the bonnet and
space provided for dropping it clear of the working area. At the front or
channel end, a minimum distance of the tube length plus 2500 mm is
considered good. This latter does not of course apply to exchangers
located in structures were a total of 1500 mm would be sufficient.
Piping connected to heat exchangers is generally simple. Piping
economy and good engineering design depend largely on knowing what
alterations can be made to exchangers. In other words, the piping
designer can influence the exchanger design. For example, the direction
of flow, nozzle locations, etc. Alterations to exchangers of course,
should not affect their duty and cost.

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Money saved on simpler piping should not be spent on costly
alterations to exchangers. The accompanying chart shows the possible
alterations that may be instigated by the piping designers to typical
shell and tube exchangers without affecting the thermal design. When
contemplating such a change it should be remembered that generally
the heated media should flow upward, and the cooled media flow
downward. This is particularly important if there is a physical change
taking place within the exchanger, such as vaporization or
condensation. Typical example of this are:

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 Reboilers where the process stream enters the shell at the bottoms as a
liquid and leaves at the top as a vapour after flowing through the tubes,
and stream enters the shell near the top of the tubes and leaves at the
bottom on the shell as condensate.

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 Condensers where the process stream enters the shell at the top as a
vapour and leaves the bottom as a liquid, whilst cooling water enters the
tubes side at the bottom and leaves at the top.

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5. Alterations That Can Be Made to Shell and Tube
Exchangers
Interchange, flowing media between the tube and shell side. This change is
often possible, more so when the flowing media are similar, for example,
liquid hydrocarbons. Preferably the hotter media should flow in the tube side
to avoid heat losses through the shell, or the necessity for thicker insulation.
 Change direction on flow on either tube or shell side. On most exchangers
in petrochemical plants, these changes are frequently possible without
affecting the required duty of the exchanger if the tubes are in double or multi
- pass arrangement and the shell has cross flow arrangement.
In exchangers where counterflow conditions can be arranged, changing of
flow direction should be made simultaneously in tube and shell. Some points
to consider when contemplating a flow change are :
 Shell leakage : When water cooling gases, liquid hydrocarbons or other
streams of dangerous nature it is better to have the water in the shell and the
process in the tubes, since any leakage of gas, etc. , will contaminate the
water rather than leaking to atmosphere.

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 High pressure conditions : It is usually more economical to have high
pressure in the tubes than in the shell as this allows for minimum wall
thickness shell.
 Corrosion : Corrosive fluids should pass through the tubes, thus allowing the
use of carbon steel for the shell.
 Fouling : It is preferable to pass the clean stream through the shell and the
dirty through the tubes. This allows for easier cleaning. Mechanical changes,
such as tangential or elbowed nozzles can sometimes assists in simplifying
the piping or lowering stacked exchangers.

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TYPICAL EXCHANGERS - SHOWS POSSIBLE ALTERATIONS FOR

BETTER PIPING

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TYPICAL EXCHANGERS - SHOWS POSSIBLE ALTERATIONS FOR
BETTER PIPING

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6. Establishing Elevations of Exchangers
Where process requirements dictate the elevation, it will usually be
noted on the P and I diagram.
 From the economic point of view, grade is the best location, where it is
also more convenient for the tube bundle handling and general
maintenance. Exchangers are located in structures when gravity flow is
required to the collecting drum, or where the outlet is connected to a
pump suction which has specific NPSH requirements. To elevate
exchangers without specific requirements, the following procedure is
recommended :
 Select the exchanger with the largest bottom connection; add to the
nozzle standout dimension ( center line of exchanger to face of flange )
the dimension thru hub of flange, elbow (1 1/2 dia ), one - half the O/S
pipe diameter and 300 mm for clearance above grade.

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 Now subtract the center line to under-side of support dimension from
above, and the dimension remaining is the finished height of the
foundation including grout.
 It is preferable if this foundation height can be made common for all the
exchangers in the bank. If this is impracticable due to extremes of shell
and/or connection pipe sizes, then perhaps two heights can be decided
upon.
 When stacking exchangers, two or three high, it is desirable that overall
height does not exceed 12’ 0” (3650 mm ) due to the problem of
maintenance, bundle pulling, etc.

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MINIMUM CLEARANCES FOR HEAT
EXCHANGERS

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7. Piping
 Plan-wise the exchanger bank should be laid out spaced as noted
previously, and all the channel nozzles on a common center line.
 This is particularly important if the cooling water headers are
underground, as the CW inlets can rise into the lower channel nozzles.
 The end of the exchanger adjacent to the rack will normally be the fixed
end, if the CW headers are underground the fixed end will become the
channel end.
 All changes proposed must be discussed fully with Process Engineer
and Client Engineer or Vessel Department.
 Lines turning right in the yard should be right from the exchanger center
line and those turning left should approach the yard on the left-hand
side of exchanger center line. Lines from bottom connections should
also turn up on the right or the left side of exchangers depending upon
which way the line turns in the yard. Lines with valves should turn
towards the access aisle with valves and control valves arranged close
to exchanger. Utility lines connecting to a header in the yard can be
arranged on any side of exchanger center line without increasing pipe
length.

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 Access to valve handwheels and instruments will influence
piping arrangement around heat exchangers. Valve handwheels
should be accessible from grade and from a convenient access
way. These access ways should be utilized for arranging
manifolds, control valves and instruments.
 In the piping arrangement, provision for tube removal access
should be provided. This means a spool piece of flanged elbow
in the pipe line connecting to the channel nozzle.
 The requirements of good piping layout generally apply to the
design of heat exchanger piping. The shortest lines and least
number of fittings - temperature permitting - will obviously
provide the most economical piping arrangement. The designer
should avoid loops, pockets and crossovers, and he should
investigate, nozzle to nozzle, the whole length of piping routed
from the exchanger to some other equipment, aiming to provide
not more than one high point and one low point, no matter how
long the line.

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 Very often a flat turn in the yard, an alternative position for control
valves or manifold, changed nozzle location on the exchanger, etc. , can
accomplish this requirement.

 Avoid excessive piping strains on exchanger nozzles from actual weight

of pipe and fittings and from forces of thermal expansion.

 For valves and blindes the best location is directly at the exchanger
nozzle. In the case of an elbow nozzle on an exchanger it should be
checked that sufficient clearances are provided between valve
handwheel and outside of exchanger. Elevated valves may require a
chain operation. The chain should hang freely at accessible spot near
the exchanger.

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 Below figure shows sketches highlighting exchanger piping details.
Orifice flanges in exchanger piping are usually in horizontal pipe runs.
These lines should be just above headroom, and the orifice itself
accessible with mobile ladder. Orifices in a liquid line and mercury type
measuring element require more height. At gas lines the U-tube can be
above the line with orifice, consequently the height is not critical. Lines
with orifice flanges should have the necessary straight runs before and
after the orifice flanges required in specification or standards.

 Locally mounted pressure - and temperature indicators on exchanger

nozzles, on the shell or process lines, should be visible from the access
aisles. Similarly gauge glasses and level controllers on exchangers
should be visible and associated valves accessible from this aisles.
When arranging instrument connections on exchangers sufficient
clearances should be left between flanges and exchanger support
between instruments and adjacent piping. Insulation of piping and
exchangers should also be taken into account.

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EXCHANGER PIPING
ARRANGEMENT

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BETTER PIPING ARRANGEMENTS

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Heat Exchanger Piping

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 THANK YOU
B.SITARAO

15-Dec-19 GS E & C India Pvt. Ltd 39