FAILURE ANALYSIS OF SHELL AND TUBE

HEAT EXCHANGER
ABSTRACT
Tar column recoiled E4509 in the phenol plant of HOCL found failed in service un like any other
exchaner s in phenol manufacturin process !Each failure very hih cost to HOCL in terms of
production loss due to do"n time for maintence and due to the loss of therminol li#uid to the process
!the loss due to each failure found to $e nearly %& '!5 chore (the cost of tu$e $undle in &&)*'+ is
&Olacks and the cost of incoloy),-5 tu$e $undle is 50 lacks! The failure analysis of this exchaner "as
found most interestin and durin these "ork modes of failures of heat exchaner "as studied to
conclude and recommend solution! .esin of exchaner "as the methodoloy used to analyse the
pro$lem! %evie"ed the history of the exchaner !compared the capacity of the exchaner in various
possi$le desin conditions !the results and conclusion of the study "ill $e very use full for HOCL in
future plannin process
CHAPTER-1
INTRODUCTION
/e look up a pro0ect on heat exchaner1 "hich is static e#uipment at Hindustan
oranic chemicals limited! Heat exchaner may $e defined as e#uipment "hich transfers the
enery from a hot fluid to a cold fluid "ith maximum rate and minimum investment and
runnin cost!
2t is used to reduce temperature of one process fluid 1 "hich is desira$le cool 1$y
transferrin heat to another fluid "hich is desira$le to heat "ith out inter mixin the fluid or
chanin the physical state of the fluid
Heatin is a vital operation in the petroleum and chemical refinery! Hence failure of
a heat exchaner result ineffective transfer of enery! 3ormal operation of heat exchaner
usually re#uires little operator attention !Ho"ever1 operatin life of a hear exchaner can $e
drastically curtailed $y improper start up and shut do"n practices! &o properly planed
executed maintenance schedule is in dispensa$le for 4very industries havin heat exchaners
on their main e#uipment in their process plant!
5 detailed maintenance schedule of plant and machinery of an industry involves
mainly monitorin "ithout distur$in the operation of the plant as a "hole!
5 pro0ect titled 67ailure analysis of shell and tu$e heat exchaner6 presents an over
vie" on different types of heat exchaners1 their purposes advantaes and disadvantaes and
the maintenance procedure adopted for smooth operation of the heat exchaner! The operation
of heat exchaner involves the production of phenol from T5% COL893!
The case study deals "ith the failure analysis of heat exchaner and desin is checked
and then proper solutions are iven to improve the effectiveness of heat exchaner!
ABOUT HINDUSTAN ORGANIC CHEMICALS LIMITED
The HOCL "as in)corporated "ith a vie" to &et up manufacturin of chemical
intermediates "ith the o$0ectives of ivin inputs to the development of do"nstream
industrial units in sector like dyes and dye intermediates1 drus and pharmaceuticals1 ru$$er
chemicals1 laminations1 solvents etc! The first unit "as set up at %asayani in 9aharashtra
"hich commenced production in '9:0! The second unit "as started at Cochin in ;erala1
"hich started production in '9,:! 2n the year '9,, a su$sidiary company vi< Hindustan
fluorocar$ons Ltd! "as commissioned at Hydera$ad! The company is presently enaed in the
manufacturin of a "ide rane of petrochemicals! The ma0or products serve as import
su$stitutes!
The HOCL is a pu$lic limited company1 "hich is manaed $y a $oard of directors
consistin of six mem$ers!
fThe manaement is assisted $y a team of "ell #ualified and experienced professionals in
technical financial safety1 marketin1 leal and other key areas!
COCHIN UNIT
Commissionin of Cochin =phenol and acetone> in '9,: headed another path $reakin
step of HOCL entry into the field of petrochemicals! The Cochin plant has an installed
*
capacity of -41000 T?5 of acetone and 409000 T? 5 of phenol@ $oth are hihly versatile
oranic chemicals! The Cochin unit comprises of three states of plant1 Ai<!
'! ?ropylene recovery plant
-! Cumene plant
*! ?henol plant
4! Hydroen peroxide
8niversal oil products inc =8O?B 8&5 One of theC "orld leaders in the field of
petrochemicals has supplied the technoloy for phenol)cumene plant! .etailed enineerin
for all the plants and also off)site "ork "as done $y 7E.O and Enineers 2ndian Ltd!
?rovided enineerin for the propylene plant and Effluent treatment plant!
The company has achieved the 2&O 900- certification for its #uality measures in the
production process and 2&O '41000 for environmental #uality standards! The entire operation
of plant is totally 5utomatic remote controlled! Continuous on)line monitorin of the process
results in perfect #uality control!
The orani<ation has hih tech safety features to minimi<e ha<ards! 9ost modem
effluent treatment plant assures complete safety to the enviroment confirmin to international
specifications! Latest enery conservation and optimisation concepts have $een incorporated
at the $einnin stae! This is the first company to export ?henol and 5cetone from !india!
&tate pollution control $oard has a"arded the company "ith the certificate of merit
for pollution control! Cochin plant "as a"arded "ith the $est pollution control measures
amon chemical plants in the state of ;erala!
PLANT LAYOUT
-5 -4
-* --
J
4
5
+
: ,
9
'0
''
-0 ' *
' 4 '5
' +
- '
-0 ' :
' ,
' 9
PARTS AND COMPONENTS
4
'! H- 0- plant
-! 9ain tankae
*! H- plant '
4! Compressor house
5! .9 plant
5! .9 plant D D)
5
+! Eoiler
:! H- ?lant -
,! 3orth Tankae
9! 7ractionation section
'0! Hot oil plant
''! Tar crackin plant
'-! Cumox plant
'*! Cumene plant
'4! &outh tankae
'5! Cumene storae
'+! Effluent treatment plant
':! Cumene storae
',! 9ain receivin station
'9! Captive po"er plant
-0! 9ain control room
-'! ?ropylene plant
--! ?ropylene storae
-*! L?F storae
-4! Coolin to"er
-5! 5dministrative $lock
-+! ?re)treatment plant
-:! /ater storae
-,! Emerency escape road!
CHAPTER-2 HEAT
EXCHANGERS
Heatin1 Condensin and Coolin are operations vital to the petroleum and chemical
refinery! These operations are accomplished mainly $y tu$ular exchaner e#uipment =&hell and
Tu$e>! Other e#uipments used for condensin and coolin are air cooled heat exchaner and
$ox coolers!
5 heat exchaner may $e defined as an e#uipment "hich transfers the enery from the
hot fluid to a cold fluid or vice versa1 "ith maximum rate and minimum investment and
runnin cost! The heat exchaner is used to reduce the temperature of one process fluid1 "hich
is desira$le to heat "ithout intermixin the fluids or chanin the physical state of the fluids!
Condensers are used to cool the temperature of a process vapour to the point "here it
"ill $ecome a li#uid $y the transfer of heat to another fluid "ithout intermixin the fluids!
/ater or air is used to condense the vapour!
2n HOCL heat exchaners are mainly used for condensin the hot vapours of the product
o$tained $y crude distillation and storin them in the li#uid form!
COMPONENTS OF HEAT EXCHANGERS
The fiure iven $elo" sho"s a typical heat exchaner and its components
+
'! &tationary Head)Channel '5! 7loatin Tu$es sheet
-! &tationary Head)Eonnel '+! 7loatin Head Cover
*! &tationary Head 7lane
4! Channel Cover
5! &tationary Head 3o<<le
+! &tationary Tu$e sheet
:! Tu$es
,! &hell
9! &hell cover
'0! &hell 7lane
''! &hell flane) %ead Head End
'-! &hell 3o<<le
'*! &hell Cover 7lane
'4! Expansion 0oint
':! 7loatin Head 7lane
',! 7loatin Head Earin .evice
'9! &plit &hear %in
-0! &lip)On Eackin 7lane
-'! 7loatin Head Cover)External
--! 7loatin Tu$e &heet &kurt
-*! ?ackin Eox
-4! ?ackin
-5! ?ackin Fland
-+! Lantern %in
-:! Tierods and &pacers
-,! Transverse EafflesGsupport ?lates
2.1 TYPES OF HEAT EXCHANGER
2n order to meet the "idely varyin applications several types of heat exchaners
have $een developed "hich are classified on the $asis of nature of heat exchane process1
relative direction of fluid motion1 desin and constructional features and physical state of
fluids!
NATURE OF HEAT EXCHANGE PROCESS.
Heat exchaners on the $asis of nature of heat exchane process are classifieds
as!
i! .irect contact opened heat exchaers!
ii! 2ndirect contact heat exchaners!
a! %eenerators!
$! %ecuperator
:
DIRECT CONTACT H! E5T EXCHANGER
7iure 2
2n a direct contact heat exchaner1 exchane of heat takes place $y direct mixin of hot
and cold fluids and transfer of heat and mass takes place simultaneously! The use of such
units is made under conditions "here mixin of t"o fluids is either harmless or desira$le!
II. Indirec C!n"c He" E#c$"n%er&
2n this type of heat exchaners1 the heat transfer $et"een t"o fluids could $e carried out
$y transmission throuh "all "hich separates the t"o fluids!
". Re%ener"!r
2n a reenerator type of heat exchaners the hot and cold fluids pass alternatively
throuh a space containin solid particles =matrix>1 these particles providin alternatively a
sink and a source for heat flo"! Example! 2C Enine and Fas Tur$ine!
The performance of these reenerators is affected $y the follo"in parameters
'! Heat capacity of %eeneratin 9aterials!
-! The rate of a$sorption
*! The release of heat!
Ad'"n"%e& !( re%ener"!r& "re )
'! Hiher heat transfer coefficient!
-! Less "eiht per ;/ of the plant!
*! 9inimum pressure loss
4! Huick response to load variations
I. Direc C!n"c He" E#c$"n%er&.
HOT WATER
5! &mall $ulk "eiht!
Di&"d'"n"%e& !( re%ener"!r& "re)
'! Costlier compared to recuperative heat exchaners!
-! Leakae is the main trou$le @ therefore1 perfect sealin is re#uired1
*. Rec+,er"!r&
%ecuperator is the most important type of heat exchaner in "hich the follo"in fluids
exchanin heat are on either side of dividin "all! These heat exchaners are used "hen t"o
fluids cannot $e allo"ed to mix i!e!1 "hen the mixin is undesira$le!
ExamplesI ) '! Oil Coolers1 2ntercoolers1 -! 5utomo$ile radiators!
5dvantaeous of a recuperator are!
'! Easy construction
-! 9ore economical
*! 9ore surface area for heat transfer!
4! 9uch suita$le for stationary plants!
2. Re-"i'e Direci!n !( (-+id .!i!n
5ccordin to relative directions of t"o fluids streams the heat exchaners are
classified into follo"in three cateories!
i! ?arallel flo" or unidirectional flo"!
ii! Counter flo"!
iii! Cross flo"
i. P"r"--e- (-!/ $e" e#c$"n%er.
J 2n parallel flo" heat exchaner as the name suest the t"o fluid streams =hot
and cold> travel in the same direction! The t"o streams enter at one end and leave at the other
end! The flo" arranements and variations of temperatures of the fluid stream in case paralled
flo" heat exchaners are sho"n in fiure! 2t is evident from the fiure that the temperature
difference $et"een the hot and the cold fluid oes on decreasin from inlet to outlet! &ince
this type of heat exchaners needs a lare areas of heat transfer it is rarely used in practice!
Example I oil coolers1 oil heaters1 "ater heaters
5s the t"o fluids separated $y a "all1 this type of heat exchaner may $e called parallel
flo" recuperated or surface heat exchaner!
|Tai
1/' ! @ !!!!!!!!!!!!!!!!!!!!inJ> in
T*i
T*!
Te.,er"+re di&ri*+i!n "-!n% +*e "#i&.
FIGURE 0
ii. C!+ner F-!/ He" E#c$"n%er.
2n a counter flo" heat exchaner1 the t"o fluid flo" in opposite direction! The hot and
cold fluid enters the opposite ends! The flo" arranements and temperature distri$ution for
such a heat exchaner are sho"n in fiure! The temperature difference $et"een the fluids
remains more or less nearly constant! This type of heat exchaner due to counter flo" ives
maximum rate of heat transfer for a iven surface area! Hence such heat exchaners are most
favored for heatin and coolin fluids!
INLET
:K7
7 S f
:EL v O8TLET
7iure 4 Counter 7lo" Heat Exchane
ii. Cr!&& F-!/ He" E#c$"n%er
2n cross flo" heat exchaners the t"o fluids =hot and cold> cross one another in space
usually at riht anles! 7i! &ho"s a schematic diaram of common arranements of cross
flo" heat exchaners!
BAFFLES
j
COLD FLUID
(IN)
M0
O
) H
3
o
N
COLD FLUID (UOT)
CROSS 7LO/ HEAT EXCHANGER Figure
5
%efer 7iure I Hot fluid flo" in the separate column and there is mixin in the fluid
streams! The cold fluid is perfectly mixed as its flo" throuh the exchaner! The temperature
of this mixed fluid "ill $e uniform across any section1 and "ill vary only in the directions of
the flo"! ExampleI coolin unit of refrieration system!
''
H 2.
c
. 122
OUTLET
COL. 7L82.
=O3>
COL. 7L82.
=8OT>
%efer fiureI 2n this case each of the fluid follo"s a prescri$ed path and is unmixed as Dit
flo"s throuh heat exchaner! Hence the temperature of the fluid leavin the heater section is
not uniform!
ExampleI automo$ile radiator
0. DESIGN AND CONSTRUCTIONAL FEATURES.
On the $asis of desin and constructional features1 the heat exchaner are classified as
under
i. C!ncenric T+*e&
2n this type1 t"o concentric tu$es are used each carryin one of the fluids! The
D direction flo" may $e parallel or counted as depicted in fiure! The effectiveness of
the heat exchaner is increased $y usin s"irlin flo"!
ii. S$e-- "nd T+*e
2n this type of heat exchaner one of the fluid flo"s throuh a $undle of tu$e J enclosed $y a
shell! The other fluid is forced throuh the shell and it flo"s over the I outside of surface of
the tu$es! &uch an arranements employed "here relia$ility and heat transfer effectiveness are
important! /ith the use of multiple tu$es heat transfer
D rate is amply improved due to increased surface area!
iii. M+-i,-e S$e-- "nd T+*e P"&&e&.
S$e-- (i+-d
f^r----S X : B ))))))))))))B
J A G I 3 4 5 3 / k
. .I
11
' P96 ^^J>6 7
!!!!2
D Eaffles
T+*e (-+id
/ \ I :
! \
\ ! I \
J-----\l-----------------------0S----
I ~ 1
7*Qv
"T#
Twti-shel) pass and four-tube pass haat exchanger
7iure +
9ultiple shell and tu$e passes are used for enhancin the overall heat transfer! 9ultiple
shell passes is possi$le "here the fluid flo"in throuh the shell is re)routed! The shell side
fluid is forced to flo" $ack and forth across the tu$es in the $y $affles! 9ultiple tu$e pass
exchaners are those "hich re)route the fluid throuh tu$es opposite direction
HOT FLUID (OUT)
$ /
One shell pass and tw t!"e pass heat e#$han%e&
Figure 7
iv! C!.,"c He" E#c$"n%er
These are special purpose heat exchaners and have a very lare transfer surface area
per unit volume of the exchaner! They are enerally employed the convective heat transfer
co)efficient associated "ith one of the fluids is much smaller than that associated "ith the
other fluid!
Example I ?late ) 7in1 flattened fin tu$e exchaners!
8. PHYSICAL STATE OF FLUIDS.
.ependin upon the physical state of the fluids the heat exchaners are classified
as follo"s I
i! Condenser
ii! Evaporators
i. C!nden&er
2n a condenser1 the condensin fluid remains at constant temperature throuh out
the exchaner1 "hile the temperature of colder fluid radually increases from inlet to
outlet! The hot fluid losses latent part of fluid "hich is accepted $y the colder fluid!
ii. E'",!r"!r&
2n this case1 the $oilin fluid remains at constant temperature "hile the
temperature of the hot fluid radually decreases from inlet to outlet!
2.2 OPERATION OF HEAT EXCHANGER.
3ormal operation of heat exchaners usually re#uires little operator
attention! Ho"ever1 operatin life of a heat exchaner can $e drastically
curtailed $y
improper start up and shut do"n practices! &ome common pro$lems are I
i! Tu$e failure due to J"ater hammerJ effect caused $y openin the shell
inlet valve too #uickly!
ii! Eendin of the pass partition plate in the partition channel due to slun
flo" from the tu$e inlet no<<le! Caused $y rapid openin of the channel
inlet valve!
iii! 2ntroduction of tu$e side fluid in a fixed tu$e sheet heat exchaner "ith
the shell side empty =since the resultin chane in the tu$e metal
temperature may over stress the tu$e to tu$e sheet 0oint resultin in
the failure>!
iv! Thermal stress induced crackin of thick sections in reion of ross
structural discontinuity1 such as tu$e sheet G channel 0unction in interal
desin1 due to rapid chanes in the fluid temperature! 2n order to avoid
such pro$lems start up and shut do"n of the e#uipments should $e
carried out in a manner consistent "ith the oriinal desin $asis!
6 5t times1 heat exchaners are desined to operate under differential
pressure is the shell and the tu$e side pressure are al"ays presents
simultaneously! The
operator should ensure that the desin assumption of differential pressure is never
violated! 2ncludin the period of start up and shut do"n1 or the period of system
pressure testin!
Other operational pro$lems in heat exchaner are flo" induced vi$ration1 rapid
tu$e failure1 corrosion and erosion of the tu$e "all1 tu$e 0oint failure1 fluid level
control difficulties and flaned 0oint leakae!
2.0. MAINTENANCE OF HEAT EXCHANGER
Operatin pro$lems in heat exchaners may $e $roadly classified into three
roups!
i! &tructural ?ro$lems
ii! ?erformance ?ro$lems
iii! 9etallurical pro$lems
i. Sr+c+r"- Pr!*-e.&
&tructural pro$lems are the most serious@ failure is often s"ift and
irreversi$le! 7ailures caused $y flo" ) induced vi$ration of heat exchaner tu$es over
shado" all other structural failures! Tu$e to tu$e sheet 0oints failure is also a fe#uent
operational pro$lem!
The other type of structural failure encountered in heat exchaner operation is
leakae from holted 0oints! Leaks fre#uently occured no<<le flanes due to moment
loadin of the 0oint caused $y thermal expansion of the interconnectin pipin! 2n
some cases1 non)temperature distri$ution in the tu$e sheet or cover in multiple pass
desin induces 0oint leakae! %eplacement of the leakin asekts "ith one havin
more appropriate loadin and relaxation properties is usually the panacea for such
structural pro$lems!
ii. Per(!r."nce Pr!*-e.&
The excessive tu$e foulin usually causes performance pro$lems
.eposition of foul ants on the inside of the tu$e surface reduces the availa$le flo"
area and increase the skin friction1 causin an increase in pressure loss and decrease in
heat transfer! 8n even rates of foulin of tu$es usually occur in units "ith lo" flo"
velocity desin! 8neven foulin may occur on the shell side of the tu$es due to a poor
$afflin scheme! /hich leads to a flo" misdistri$ution! Hihly non)uniform foulin
on severely modifies the metal temperature profile in some tu$es resultin in lare
tu$es ) to tu$e sheet 0oint leads!
Thermal stresses in the internal of the heat exchaner can cause serious
deradation of heat duty! The most o$vious example is failure of "elds 0oinin pass
partition plates to each other and to the channel!
iii. Me"--+r%ic"- ,r!*-e.&
&tress corrosion1 alvanic corrosion1 and erosion are the most re#uently
reported metallurical pro$lems! Care in the selection of material can eliminate most
of these pro$lems! /here the alvanic action cannot $e completely eliminated! The
use of "aster anode is recommended!
AD7ANTAGES AND DISAD7ANTAGES OF HEAT EXCHANGERS
Ad'"n"%e&
'! Enery &avins!
-! 3o 5dditional $oilers are needed!
*! Condensation provides less space and safety operations!
Di&"d'"n"%e&
'! The use of heat exchane causes the flo" restriction1 hence1 additional
pumps are re#uired to correct the flo"!
'! 7riction losses
-! Operation difficulties such as flane leakae!
*! 7ailure of heat exchaner!
9. 9aintenance cost and operatin cost!
2.8 FOULING
2n a heat exchaner durin normal operations the tu$e surface ets covered $y
deposits of ash1 soot1 and dirt and scale etc! This phenomenon of rust formation and
deposition fluid impurity is called foulin!
(!+-in% Pr!ce&&e&
'! ?recipitation or crystalli<ation foulin
-! &edimentation or particulate foulin
*! Chemical reaction foulin or polymeri<ation
4! Corrosion foulin
5! Eioloical foulin
+! 7ree<e foulin
P"r".eer "((ecin% (!+-in%
'! Aelocity
-! Temperature
*! /ater chemist
4! Tu$e materiaC
Pre'eni!n !( (!+-in%
The follo"in methods may $e used to keep foulin minimum
'! .esin of heat exchaner
-! Treatment of process system
*! Ey usin clean system
Pr!,erie& ! *e c!n&idered (!r &e-eci!n !( ."eri"-& (!r $e" e#c$"n%:
'! ?hysical properties
-! 9echanical ?roperties
*! Climatic ?roperties
4! Chemical Environment
5! Huality of &urface finish
+! &ervice 7ile
:! 7reedom from 3oise
,! %elia$ility
C!..!n ("i-+re ! $e" e#c$"n%er&
'! Checkin of tu$es either expected or extra ordinary
)
!
-! Excessive transfer rates in heat exchaner
*! 2ncreasin the pump pressure to maintain throuh out
4! 7ailure to clean ru$es at reularly scheduled intervals!
5! Excessive temperature in heat exchaner
+! Lack of control of heat exchaners atmosphere to retard scalin!
:! 2ncreased product temperature over a safe desin unit
,! 8nexpected radiation from refractory surface!
9! 8ne#ual heatin around the circumferences or alon the lenth tu$es!
O'er"-- He" Tr"n&(er C!e((icien
Heat transfer in heat exchaner takes place mainly $y conduction and convection!
2f a tu$e "all as separates the fluids sho"n in fiure! The overall heat transfer co
efficient is iven $y
Inner &+r("ce;
8i
'Ghi L riGk 2n =ro Gri> L riGro x 'Gho
O+er &+r("ce
8o
=ro Gri> 'Ghi L roGkxln = roGri> x 'Gho
<$ere
8i Overall heat transfer coefficient inside the tu$e
8o R Overall heat transfer coefficient outside the tu$e
Hi R Local convective heat transfer coefficient inside the tu$e
ho R Local convective heat transfer coefficient inside the tu$e
ri
R 2nside radius of the tu$e
ro Outside radius of the tu$e
k R Conductive heat transfer coefficient of tu$e material!
8! 5! R 8o5o
<$ere
5 R - r! L1 5rea inside the tu$e
5 R - r L1 5rea outside the tu$e
0 % &
' i n!7n= ' hi
Ai -TT;L h'A
7iure ,
C!n&ider"i!n !( (!+-in% !r &c"-in%
.ue to foulin the thermal resistance is increased and eventually the performance of heat
exchaners lo"ers! &ince it is difficult to ascertain the thickness and thermal conductivity of
the scale deposits1 the effect of sale on heat flo"in considered $y specifyin an e#uivalent
scale heat transfer coefficient hs! 2f hs0 and hsH $e the heat transfer coefficient for the scale
deposited on the inside and
outside surface respectively1 than the thermal resistance to scale formation on the inside
surface =%&0> and outside surface =%&0> are iven $y
%& ) MPMMMM1
5 h s !
i i
%&o R ' !
5h s
O 0
The reciprocal of the heat transfer coefficient1 hs is called the follo"in factor % f
Thus % f R ' Ghs m
-o
cG"
7oulin factors are determined experimentally $y testin the heat exchaner in
$oth clean and dirty continuous! The foulin factor % f is thus
defined as I
%f R= l G h r > R l G 8H ! t ) 'G8 !
v
J dirty clean
The heat transfer considerin the thermal resistance due to scale formation1 is
iven $y
H
R
MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM0!4>MMMMMMMMMMMMMMMMMMMMMMMMMM1
l G 5! h L ' G 5! h s ! L 'G- ;Lx 2 n = r r!>LlG5 hs L 'G5 h
' ' ' '
v
O! V 0 0 0 0
The overall heat transfer coefficient 8 $ased on the inner and outer surface of the
inner tu$e is iven $y I
8i ) MMMMMMMMMMMMMMMMMMMMMMMMMMMMM'MMMMMMMMMMMMMMMMMMMMMMMM1
l G h ! L %! L r! ;2 n = r !r!> L r! G r ! L%!! Lr ! G r x l G h
' I I
v
O ; ' O ' 0 ' 0 O
8o MMMMMMMMMMMMMMMMMMMMMMMMM'MMMMMMMMMMMMMMMMMMMMMMMMMMMMM1
= r G r ! > x l G h ! L= r ! r ! > x %f ! L r G k x 2n = r G r !> L %f L 'Gh
v
0 '
G
'
v
O ; ' 0
v
0 ; 0
2.9 TYPES OF SER7ICES
There are various types of services in "hich tu$ular exchaners are used in
petroleum and chemical processes listed $elo"!
'. He" E#c$"n%er) 2t used to reduce the temperature of one process fluid1 "hich
is desira$le to cool $y transferin heat to another fluid "hich is desira$le to heat
"ithout intermixin the fluids or chanin the physical state of the fluid!
-! C!nden&er) are used to reduce the temperature of a process vapour to the
point "here it "ill $ecome a li#uid $y the transfer of heat to another fluid "ithout
intermixin the fluid! /ater or air is used to condense process vapour! The function
results in a chanin the physical state of the process vapour!
*! C!!-er&) They are used to cool a heat process li#uid to a lo"er more desira$le
temperature $y the transfer of heat to another fluid "ithout intermixin the fluid! /ater or
air is usually used to cool process li#uids! This function does not result in a chanin
physical state of the process li#uid!
4! EvaporatorI are used in the vapori<ation of a process li#uid $y either a process or
utility li#uid or vapor "ithout intermixin the fluid! 9any aporators are steam to vapori<e
a process li#uid! This function results in a chanin the physical state of the process
vapour! /hen steam is used condensate is usually formed!
5! %e ) $oilers I are used in the partial vapori<ations of a process fluid $y either a
process or utility li#uid or vapor! 9any re)$oilers are steam to vapori<e a process li#uid!
2.> TYPES OF FAILIURE
Sre&& C!rr!&i!n Cr"c?in%
&tress corrosion crackin is a failure mechanism that is caused $y environment1
suscepti$le material1 and tensile stress! Temperature is a sinificant environmental factor
affectin crackin!
7or stress corrosion crackin to occur all three conditions must $e met
simultaneously! The component needs to $e in a particular crack promotin environment1 the
component must $e made of a suscepti$le material1 and there must $e tensile stresses a$ove
some minimum threshold value! 5n externally applied load is not re#uired as the tensile
stresses may $e due to residual stresses in the material! The threshold stresses are commonly
$elo" the yield stress of the material!
Sre&& C!rr!&i!n Cr"c?in% F"i-+re&
&tress corrosion crackin is an insidious type of failure as it can occur "ithout an
externally applied load or at loads sinificantly $elo" yield stress! Thus1 catastrophic failure
can occur "ithout sinificant deformation or o$vious deterioration of the component! ?ittin
is commonly associated "ith stress corrosion crackin phenomen
7iure!9 &tress Corrosion Crackin
5luminum and stainless steel are "ell kno"n for stress corrosion crackin pro$lems!
O"ever1 all metals are suscepti$le to stress corrosion crackin in the riht environment!
C!nr!--in% Sre&& C!rr!&i!n Cr"c?in%
There are several methods to prevent stress corrosion crackin! One common method
is proper selection of the appropriate material! 5 second method is to remove the chemical
species that promotes crackin! 5nother method is to chane the manufacturin process or
desin to reduce the tensile stresses! 59C can provide enineerin expertise to prevent or
reduce the likelihood of stress corrosion crackin in your components!
F"i-+re& !( He" E#c$"n%er&
S!.e c!..!n c"+&e& !( ("i-+re& in $e" e#c$"n%er& "re -i&ed *e-!/)
S ?ipe and tu$in imperfections
S /eldin
S 7a$rication
S 2mproper desin
S 2mproper materials
S 2mproper operatin conditions
S ?ittin
S &tress)corrosion crackin =&CC>
S Corrosion fatiue
Feneral corrosion
Crevice corrosion
.esin errors
&elective leachin1 or dealt
Erosion corrosion
<e"r F"i-+re&
/ear may $e defined as damae to a solid surface caused $y the removal or
displacement of material $y the mechanical action of a contactin solid1 li#uid1 or as! 2t may
cause sinificant surface damae and the damae is usually thouht of as radual
deterioration! /hile the terminoloy of "ear is unresolved1 the follo"in cateories are
commonly used!
Fi%+re.1@ <e"r F"i-+re&
Ad$e&i'e /e"r
5dhesive "ear has $een commonly identified $y the terms allin1 or sei<in
A*r"&i'e /e"r
5$rasive "ear1 or a$rasion1 is caused $y the displacement of material from a solid
surface due to hard particles or protu$erances slidin alon the surface
Er!&i'e /e"r
Erosion1 or erosive "ear1 is the loss of material from a solid surface due to relative
motion in contact "ith a fluid that contains solid particles! 9ore than one mechanism can $e
responsi$le for the "ear o$served on a particular part!
Piin% C!rr!&i!n
?ittin is a locali<ed form of corrosive attack! ?ittin corrosion is typified $y the
formation of holes or pits on the metal surface! ?ittin can cause failure due to perforation
"hile the total corrosion1 as measured $y "eiht loss1 miht $e rather minimal! The rate of
penetration may $e '0 to '00 times that $y eneral corrosion!
?its may $e rather small and difficult to detect! 2n some cases pits may $e masked due to
eneral corrosion! ?ittin may take some time to initiate and develop to an easily vie"a$le
si<e!
?ittin occurs more readily in a stanant environment! The aressiveness of the corrodent
"ill affect the rate of pittin! &ome methods for reducin the effects of pittin corrosion are
listed $elo"I
oyin
S %educe the aressiveness of the environment
S 8se more pittin resistant materials
Uni(!r. C!rr!&i!n
8niform or eneral corrosion is typified $y the rustin of steel! Other examples of
uniform corrosion are the tarnishin of silver or the reen patina associated "ith the corrosion
of copper! Feneral corrosion is rather predicta$le! The life of components can $e estimated
$ased on relatively simple immersion test results! 5llo"ance for eneral corrosion is
relatively simple and commonly employed "hen desinin a component for a kno"n
environment!
&ome common methods used to prevent or reduce eneral corrosion are listed $elo"I
S Coatins
S 2nhi$itors
S Cathodic protection
S ?roper materials selection
Fi%+re.11 Uni(!r. C!rr!&i!n
C!rr!&i!n F"i-+re&
Corrosion is chemically induced damae to a material that results in deterioration of the
material and its properties! This may result in failure of the component! &everal factors should
$e considered durin a failure analysis to determine the affect corrosion played in a failure!
Examples are listed $elo"I
S Type of corrosion
S Corrosion rate
S The extent of the corrosion
S 2nteraction $et"een corrosion and other failure mechanisms
Corrosion is is a normal1 natural process! Corrosion can seldom $e totally prevented1 $ut it can
$e minimi<ed or controlled $y proper choice of material1 desin1 coatins1 and occasionally $y
chanin the environment! Aarious types of metallic and nonmetallic coatins are reularly
used to protect metal parts from corrosion!
&tress corrosion crackin
necessitates a tensile stress1 "hich may $e caused $y residual stresses1 and a specific
environment to cause proressive fracture of a metal! 5luminum and stainless steel are "ell
kno"n for stress corrosion crackin pro$lems! Ho"ever1 all metals are suscepti$le to stress
corrosion crackin in the riht environment!
La$oratory corrosion testin is fre#uently used in analysis $ut is difficult to correlate "ith
actual service conditions! Aariations in service conditions are sometimes difficult to duplicate
in la$oratory testin!
C!rr!&i!n F"i-+re& An"-A&i&.
2dentification of the metal or metals1 environment the metal "as su$0ected to1 forein matter
andGor surface layer of the metal is $eneficial in failure determination! Examples of some
common types of corrosion are listed $elo"I
S 8niform corrosion
S ?ittin corrosion
S 2nterranular corrosion
T Crevice corrosion
S Falvanic corrosion
S &tress corrosion crackin
3ot all corrosion failures need a comprehensive failure analysis! 5t times a preliminary
examination "ill provide enouh information to sho" a simple analysis is ade#uate!
F"i%+e F"i-+re&
9etal fatiue is caused $y repeated cyclin of of the load! 2t is a proressive locali<ed
damae due to fluctuatin stresses and strains on the material! 9etal fatiue cracks initiate
and propaate in reions "here the strain is most severe!
The process of fatiue consists of three staesI
2nitial crack initiation
?roressive crack ro"th across
7inal sudden fracture of the remainin cross section
S
St&ess
Gr",$-1 S-N c+r'e
&chematic of &)3 Curve1 sho"in incr!ease in fatiue life "ith decreasin
stresses
Sre&& R"i!
The most commonly used stress ratio is %1 the ratio of the minimum stress to the
maximum stress =&minG&max>!
S 2f the stresses are fully reversed1 then % R )'!
S 2f the stresses are partially reversed1 % R a neative num$er less than '!
Cycles to
7ailure 3
S 2f the stress is cycled $et"een a maximum stress and no load1 % R <ero!
S 2f the stress is cycled $et"een t"o tensile stresses1 % R a positive num$er less than '!
Aariations in the stress ratios can sinificantly affect fatiue life! The presence of a mean
stress component has a su$stantial effect on fatiue failure! /hen a tensile mean stress is
added to the alternatin stresses1 a component "ill fail at lo"er alternatin stress than it does
under a fully reversed stress!
t% C($les t Fail!&e
Pre'enin% F"i%+e F"i-+re
The most effective method of improvin fatiue performance is improvements in desinI
S Eliminate or reduce stress raisers $y streamlinin the part
S 5void sharp surface tears resultin from punchin1 stampin1 shearin1 or other
processes
S ?revent the development of surface discontinuities durin processin!
S %educe or eliminate tensile residual stresses caused $y manufacturin!
S 2mprove the details of fa$rication and fastenin procedures
F"i%+e F"i-+re An"-A&i&
9etal fatiue is a sinificant pro$lem $ecause it can occur due to repeated loads $elo" the
static yield strenth! This can result in an unexpected and catastrophic failure in use!
Eecause most enineerin materials contain discontinuities most metal fatiue cracks initiate
from discontinuities in hihly stressed reions of the component! The failure may $e due the
discontinuity1 desin1 improper maintenance or other causes! 5 failure analysis can determine
the cause of the failure!
Hih Temperature 7ailure 5nalysis
Creep occurs under load at hih temperature! Eoilers1 as tur$ine enines1 and ovens are some
of the systems that have components that experience creep! 5n understandin of hih
temperature materials $ehavior is $eneficial in evaluatin failures in these types of systems!
7ailures involvin creep are usually easy to identify due to the deformation that occurs!
7ailures may appear ductile or $rittle! Crackin may $e either transranular or interranular!
/hile creep testin is done at constant temperature and constant load actual components may
experience damae at various temperatures and loadin conditions!
Cree, !( Me"-&
Hih temperature proressive deformation of a material at constant stress is called creep! Hih
temperature is a relative term that is dependent on the materials $ein evaluated! 5 typical
creep curve is sho"n $elo"I
Gr",$-2 &r"in-i.e c+r'e
2n a creep test a constant load is applied to a tensile specimen maintained at a constant
temperature! &train is then measured over a period of time! The slope of the curve1 identified
in the a$ove fiure1 is the strain rate of the test durin stae 22 or the creep rate of the material!
?rimary creep1 &tae 21 is a period of decreasin creep rate! ?rimary creep is a period
of primarily transient creep! .urin this period deformation takes place and the resistance to
creep increases until stae 22! &econdary creep1 &tae 221 is a period of rouhly constant creep
rate! &tae 22 is referred to as steady state creep! Tertiary creep1 &tae 2221 occurs "hen there is
a reduction in cross sectional area due to neckin or effective reduction in area due to internal
void formation!
Sre&& R+,+re
&tress rupture testin is similar to creep testin except that the stresses used are hiher
than in a creep test! &tress rupture testin is al"ays done until failure of the material! 2n creep
testin the main oal is to determine the minimum creep rate in stae 22! Once a desiner
kno"s the materials "ill creep and has accounted for this deformation a primary oal is to
avoid failure of the component!
Time
))))))))))
7ract
ure
2nitial
Load
1.
Strai
Typical
&tress
%upture .ata
D ? i J 2 2
9
O
T"1
ters
W
2
ir
5
)'
*
)'
)
W St&ess &!pt!&e ti+e, h&
Gr",$-# &re&& - &re&& r+,+re i.e
&tress rupture tests are used to determine the time to cause failure! .ata is plotted
lo)lo as in the chart a$ove! 5 straiht line is usually o$tained at each temperature! This
information can then $e used to extrapolate time to failure for loner times! Chanes in slope
of the stress rupture line are due to structural chanes in the material! 2t is sinificant to $e
a"are of these chanes in material $ehavior1 $ecause they could result in lare errors "hen
extrapolatin the data!
CHAPTER - 0 SPECIFICATION OF HEAT EXCHANGER PARTS
THE CHANNEL CO7ER
Channel covers are usually circulars in desin and fa$ricated out of the same
plate material as the channel! The thickness of the flat channel covers in determined from
code or TE95 formulas "hichever is reater! 7or sinle pass channels or other in "hich
there is no pass partition asket seal aainst the channel cover! Only the code formula needs
$e considered! The effective thickness of the flat channel covers is the thickness measured at
the $ottom of the pass partition rove minus the tu$e side corrosion allo"ance in excess of
the rove depth! Channel covers are re#uired to $e provided "ith approximately *G'+ 6
=40,m> deep roves for pass partition plates!
THE CHANNEL
The channel is usually rod plate material "ith the edes "elded toether $y a full
penetration fusion "eld! This "eld is a lonitudinal seam! The stationary flanes of the
channel are "elded in the same manner are circumferential "eld seam!
The pass partitions in the channel are flat plate and the same material as the channel!
They are usually attached to the inside of channel $y fall penetration fusion "eld! The
nominal thickness of channel pass partitions shell not $e less than that sho"n in the ta$le
iven $elo"! ?artition plates may $e tapered to asket "idth at the contact surface!
LO3F2 T8.2 35L /EL. &E59
St&es
s
C-ANNEL
(i%+re-12
Mini.+. ,"&& ,"rii!n ,-"e $ic?ne&&
N!.in"- &iBe c"r*!n &ee- "--!A
Le&& L28C 041C DC
28C! >@C '2( 041C
THE SHELL
Construction and fa$rication of an exchaner are similar to that of pressure vessel! The
exchanerJs shell material is usually rolled plate material! The plate edes are "elded
toether $y a full penetration fusion "eld! This "eld is the lonitudinal "eld seam! The
exchaner may re#uire t"o or more shell rins 0oined toether to form a sinle exchaner
shell! The "elds 0oinin the rins toether are circumferential "eld seams! 7or small
diameter exchaners1 seamless pipe is usually used!
The shell thickness of the exchaner is determined $y code desin formulas plus
corrosion allo"ance1 $ut is no case shall the nominal thickness of the shell $e less than that
sho"n in the TE95 ta$le iven $elo"!
g)*+e, *e),i-g
*ur.)ce
TEMA Mini.+. &$e-- N!.in"- $ic?ne&&
C"r*!n &ee- N!.in"- &$e--
D .iameter pipe plate 5lloy
,6)'-6 ,CH!*0 'G,6
4
'*6)-96
*G,6 *G,6 *G'+6
EXCHANGER SHE""
(i%+re-0
*06)*96 :G'+6
406)+06
. l
A" 5G'+6
7or 5E& exchaners and the other types of exchaners flanes are in accordance
"ith code desin rules! 7laes are throuh)$olted type unless other"ise specified! The
shell flane to shell "elds are circumferential "eld seams and are also full penetration
fusion "elds!
N!e I 5ll "eds on the inside of the exchaner shell are round flush "ith the $ase
material so the tu$e $undle "ith slide in and out of the shell "ithout hanin up!
SHELL CO7ER
The shell cover thickness is determined $y code desin formulas plus corrosion
allo"ance! 7or shell covers1 TE95 re#uires the thickness of the shell cover to $e at
least e#ual to the thickness of the shell cover to $e least e#ual to the thickness of the
shell as sho"n iven previous pae! The material used to fa$ricate the shell cover is
the same as the shell material!
The $ody of the shell cover is usually roved plate material "ith the edes
toether "ith a full penetration fusion "eld! The head used for the shell cover is
normally a flaned and dished type! Eoth the head the flane are "elded to the $ody
of the head "ith a full penetration fusion "eld!
NOEELES
3o<<les may $e fa$ricated out of pipe couplin1 $uilt up construction1 lon "eld neck
flanes as interally reinforced no<<les! The interrally reinforced necks are preferred! &hed
no<<les are not permitted to protrude $eyond the inside contour of the shell! Channel no<<les
may protrude inside the channel1 provided vent and drain connections are flush "ith the inside
contour of the channel! Aents and drains on the shell side of the exchaner not other "ise
vented or drained $y no<<les are re#uired to have a *G46 connections may $e provided at the
manufacturers o$tain!
;@ i i
/
i / D FACT
U L
P '
P
0
) *
T 2
/2TI7 HOLE
i
! 0
i
P i
k! ! my.
..........
JKm.^Ju
'
L1
N
3o<<le
Fi%+re 18
7lat on raised flanes are re#uired $et"een intermediate no<<les of stacked units! Eoltin
in flanes of matin connections $et"een stacked exchaners is re#uired to $e remova$le
"ithout movin the exchaners! 5ll no<<les are re#uired to $e full penetration fusion "elds
"ith the inside of the "eld to $e flush on all shell connections!
TUBE SHEETS
The tu$e $undle of the 5E& exchaner has a stationary tu$e sheet on the channel end of
the $undle and a floatin head tu$e sheet on the $ack end of the $undle! The diameter of the
floatin head tu$e sheet is small enouh to pass throuh the cylindrical shell! The diameter of
the stationary tu$e sheet is larer enouh to $ear on a asketed surface of the shell flane )
stationary end! Tu$e sheets may $e the same material as the tu$es or may $e of a different
metallury that the tu$e! Eecause of economics a cooler or condenser may have $rass tu$es
and car$on steel tu$e sheet! 7rom corrosion standpoint it is not ood to mix metallury like
this in "ater service $ecause of alvanic corrosion $et"een the $rass tu$e and car$on steel
tu$e sheet! Life of the car$on steel tu$e sheet can $e extended $y addin cathodic protection
in the channel and the floatin head durin fa$rication or after the unit arrives at the refinery!
Tu$e sheets may also $e alloy lined $y claddin or "eld metal overlay for corrosion
resistance! Claddin should $e interally and continuously $onded to the $ase material of the
tu$e sheet and is not counted for the strenth is adds to the $ase material! The TE95 nominal
claddin thickness on the tu$eside face of a tu$e sheet is to $e note than 5G'+6 =,mm> "hen
tu$es are expanded only1 and 'G,6 "hen tu$es are "elded to the tu$e sheet! The nominal
claddin thickness of the shell side face shall not $e less than *G,6! 5ll surfaces exposed to the
fluid includin asket seatin surfaces1 are re#uired to have at least 'G,6 nominal thickness of
claddin!
The circular tu$e sheets are machined to the re#uired dimensions includin asket
seatin surfaces! Tu$e holes are drilled and reamed for the tu$es! 2f the tu$e sheets re#uire
heat treatment1 the final hole si<e is o$tained $y reamin after heat treatment!
Tu$es are usually attached to the tu$e sheet $y rollin! 5 suita$le roller type tu$e
expander should $e used to tihten tu$e! Care must $e taken to insure that the tu$es are not
over expanded1 thus avoidin possi$le damaes to the tu$e!
5ll tu$e sheet tu$e holes for expanded 0oints are re#uired $y TE95 to have at least t"o
machined rooves each1 approximately 'G,6 =*mm> "ide $y 'G+46 deep! Tu$es are normally
expanded into the tu$e sheet for a lenth not less than -6 or tu$e sheet thickness minus 'G,6
"hichever is smaller! 2n no case should the expanded portion of the tu$e extend $eyond
the shell side face of the tu$e sheet! The expandin procedure should provide uniform
expansion throuhout the expanded portion of the tu$e "ithout sharp transition to the
unexpanded portion! Tu$es for the top tu$e sheet in vertical exchaners are re#uired to $e
flush to facilitate drainae! Tu$es may also $e rolled and seal "elded for additional leak
tihtness or strenth "elded!
BAFFLES AND TUBE SUPPORTS
Eaffles are used to channel the shell side fluid around the tu$es from the shell inlet to the
shell outlet! The various types of $affles used in tu$e $undle construction are illustrated in
fiure! The semental or multi)semental type of $affles or tu$e support plate is standard1 $ut
other type of $affles may $e used! The $affles are circular plate "ith a sement openin and
the heiht of this openin is a percentae of the shell inside diameter! The $affle material may
$e the same as the shell or tu$e material1 dependin on "hat "as specified $y the purchaser!
Eaffles tu$e holes are usually drilled into the $affles! /hen the maximum unsupported
tu$e lenth is 9'4 mm or less1 or tu$es larer in diameter than ** mm diameter and reater1
standard tu$e holes are drilled 0!4 mm over the outer diameter of the tu$es! 7or pulsatin
conditions1 tu$e holes may $e drilled smaller than standard! 5ll $affle holes drillin has a
maximum over tolerance of 0!-5 mm!
S"nd"rd cr!&& *"((-e "nd &+,,!r ,-"e c-e"r"nce F"-- di.en&i!n& "re
in inc$e&=GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG
3ominal shell inside diameter
.esin inside diameter of shell minus $affle
out side diameter
,)'* 0!'00
'4)': 0!'-5
',)-* 0!'5
-4)*9 0!':5
40)54 0!--5
55)+0 0!*0
T"*-e-1 S"nd"rd cr!&& *"((-e "nd &+,,!r ,-"e c-e"r"nce
The desin inside diameter of the pipe shell is the nominal outside diameter of the pipe1 minus
t"ice the nominal "all thickness! The desin inside diameter of a plate shell is the specified
inside diameter1
&pecial desin consideration must $e iven to $affles and support plates su$0ected to
pulsations1 to $affles and support plates enain tu$es1 and to laonitudinal $affles su$0ected
to lare differential pressures due to hih shell side fluid pressure drops!
Eaffles and support plate spacin are normally spaced uniformly1 spannin the effective
tu$e lenth! /hen the desin is such that this cannot $e done1 the $affles nearest the ends of
the shell are and tu$e sheets are located as close as parctical to the shell no<<les! The
remainin $affles are then spaced uniformly!
THE RODS AND SPACERS
The $affles or support plates of a $undle are tied toether "ith tie rods and spacers! They
hold the $affles or supports securely in position durin the fa$rication of the $undle! The tie
rods are normally rod material and the spacers tu$in! The material of $oth should $e similar
to that of the tu$es! 2n some cases1 $ecause of economic1 some refineries have car$on still tie
rods and spacers in a $rass tu$e $undle!
SEALING DE7ICES
2n addition to $affles it may $e necessary to prevant excessive fluid $y passin around or
throuh the tu$e $undle that has a lonitudinal $affle or $affles1 particularly in the case of
type 71 F1 H or P shells! The most common sealin device is seal strips $ut tie rods "ith
spacers1 dummy tu$es or any com$ination of these may $e used! &eal strips are made up of
very thin metal strips sand"iched toether and $olted to $oth side of the $undle! /hen the
$undle is inserted into its shell the seal strips make contact "ith the side of the shell1 thus
providin the seal!
IMPINGEMENT BAFFLES AND EROSION PROHECTION
5n impinement plate1 or other means to protect or curtail erosion to the shell side of the
tu$e $undle from incomin fluids may $e re#uired if they exceeds certain entrance line values
as determined $y a formula iven into the TE9 standard! 3ormally the impinement plate is
made out of plate material similar to the $undle material and is either "elded or $ra<ed to the
tie rods of the $undle! The impinement plate should never $e attached to the tu$es! 5
properly desined diffuser may $e used to reduce line velocities at the shell entrance or inlet
no<<le! The diffuser material should $e the same as the shell material!
FLOATING HEAD
The most common type of floatin head is the flaned and shallo" dished! The floatin
head may $e $olted directly to the floatin head tu$esheet of the $undle or may $e attached $y
a $ackin rin device! The material of construction for split rins or other internal floatin
head $ackin devices is the same as the material used for sheel interior!
?ass partition1 plates1 "hen re#uired1 are usually plate material "hich is cut to $e contour
of head and attached to the head $y a full penetration fusion "eld!
BOLTING
Except for special desin consideration1 flanes are throuh $olted "ith stud $olts
threaded full lenth "ith a remova$le not on each end! &tud $olt lenth should $e such that
the nuts are fully enaed and pro0ect throuh approximately *!- mm on each end! The
minimum permissi$le TE95 $olt diameter is *G46 ='9 mm>! 7or si<es '6 =-5!4 mm> ans
smaller1 coarse thread series is re#uired $y TE95 and for larer si<es an , ) pitch thread
series is re#uired!
CORROSION ALLO<ANCE
Pre&&+re P"r&) 5ll car$on steel pressure parts1 except tu$es1 have a corrosion allo"ance of
'G,6 =*!-mm> unless service conditions make a different allo"ance more suita$le and
specified $y the purchaser!
Inern"- C!'er&) 2nternal covers are to have a corrosion allo"ance on each side!
T+*e S$ee&) Tu$e sheets are to have corrosion allo"ances on each side "ith provisions that1
on the rooved side of a rooved tu$e sheet1 the depth of the pass partition roove may $e
considered as avila$le for corrosion allo"ance!
E#ern"- C!'er&) /here flat external covers are rooved1 the depth of the roove may $e
considered as availa$le for corrosion allo"ance!
End F-"n%e&) Corrosion allo"ance apply only to $e inside diameter of the flanes!
N!n Pre&&+re ,"r&) 3on pressure parts such as tie rods1 spacers1 $affles and support plates
have no corrosion allo"ances!
F-!"in% He"d B"c?in% De'ice) 7loatin head $ackin devices and internal $oltin have no
corrosion allo"ance!
P"&& P"rii!n P-"e&) ?ass partition plates have no corrosion allo"ance unless1 specified $y
the purchaser!
A--!A P"r&) 3o corrosion allo"ance is added to alloy parts except as specified $y the
purchaser! /hen "eld metal overlay claddin or claddin is used1 the nominal thickness of
the claddin is usually the availa$le corrosion allo"ance!
T+*e&) 8nless specified $y the purchaser the corrosion allo"ance for tu$es may $e ar$itrarily
set at $et"een one half and one third the oriinal nominal thickness1 dependin on service and
experience!
SUPPORTS AND FOUNDATIONS
5ll tu$ular exchaners are re#uired to $e provided "ith supports "hich are desined to
avoid under stress or deflection in either the supports or shell! Hori<ontal units are provided
"ith at least t"o supportin saddles "ith holes for anchor $olts! The holes in at least one of
the supports are re#uired to $e elonated to provide for expansion of the shell! The saddles are
mode of plate material rolled to the O.! The plate material should $e the same material as the
shell! The saddle is attached to the shell of the exchaner $y a full filled "eld and is "elded
all the "ay around! 5 vent hole or tell tale hole is drilled in the $ottom of the saddle1 max si<e
'G46 =+!4 mm>1 "hen the saddle is "elded all the "ay around!
2n some cases1 a ap in the "eld may $e left near the $ottom of the saddle for ventin!
7or vertical exchaners1 supports of sufficient si<e are re#uired to carry the unit in a
supportin structure of sufficient "idth to clear shall flanes!
7oundation must $e desined so that the exchaner "ill not settle and cause the pipin to
transmit excessive strains to the no<<les of the exchaner! 7oundation $olts should $e set to
allo" for settin inaccuracies! 2n concrete footins1 pipe sleeves at least one si<e larer than
the $elt diameter slipped over the $olt and cast in plate are $est suited for this purpose1 as they
allo" the $olt centre to $e ad0usted after the foundation is set!
7oundation $elts should $e loosened at one end of the exchaner to allo" free expansion
of the shell! The slotted helps in the supports are provided for this purpose!
The exchaner must $e set level and s#uare so that pipe connections may $e made
"ithout forcin!
GROUND <IRE
5ll exchaners are provided "ith a round "ire in case they are struck $y lihtin! This
round "ire is attached to one of the foundation $ul$s on one end of the exchaned and runs
do"n into the round!
LIFTING DE7ICES
Channel1 $onnets1 floatin heads and shell covers "hich "eiht over to pounds are
re#uired to the provided "ith liftin les1 rins or tapped holes for eye$olls for liftin!
EXCHANGER GASIETS
5ll askets are re#uired to $e made in one piece1 $ut does not exclude asket made
interal $y "eldin! 9etal 0acketed or solid metal askets are re#uired for floatin head 0oints1
all 0oints for pressures of <oops @ and over1 and for all 0oints in contact "ith hydrocar$ons!
Other asket material may $e specified $y areement $et"een the purchaser and the
manufacture to meet special service conditions and flane desin! /e t"o askets are
compressed $y same $oltin1 asket material and areas shall $e selected so that $oth asket
seal1 $ut neither is crushed at the re#uired $olt load!
CHAPTER -8 PROBLEM
DEFINITION
2n HOCL a shell and tu$e heat exchaner is used in the production line of phenol! Hot
oil at *-,VC and '0!5 kGcm- is passin throuh the exchaner tu$es!&&*'+ material is used
in the tu$es! '-0 tu$es at the top of the heat exchaner fails reularly and hence the plant have
to $e closed do"n for at least - days on each failure! The failure causes lose of hot oil
=therminol> "hich cost approximately %s ,50 per litre! 5$out 'cm drop in oil level costs a$out
5 lakhs!
CHAPTERS CAUSES OF
FAILIURE
5!' Ai$ration
.amae from the tu$e vi$ration has $ecome an increasin phenomenon as
heat exchaner si<es and #uantities of flo" have increased !The shell side flo"
$uffle confiuration and unsupported tu$e span are of prime consideration
mechanism of tu$e vi$ration are follo"s!
7!re# &$e--in%
2 he vortex shellin fre#uency of the fluid in cross flo" over the tu$es may coincide
"ith a natural fre#uency of tu$e and excite lare resonant vi$ration amplitudes
F-+id e-"&ic c!+,-in%
7luid flo"in over tu$es causes them to vi$rate "ith a "hirlin motion !the
mechanism of fluid elastic couplin occurs !/hen a critical velocity exceed and the vi$ration
then $ecome self exited and ro"s in amplitude !This mechanism fre#uently occurs in process
heat exchaners "hich suffer vi$ration damae !
Pre&&+re (-+c+"i!n
Tur$ulent pressure fluctuations "hich develop in the "ake of a cylinder or are carried
to the cylinder from upstream may provide a potential mechanism for tu$e vi$ration !The tu$e
respond to the portion of the enery spectrum that is close to their natural fre#uency!
9.2 C!rr!&i!n
Hih temperature in the system can cause oxidation due to its cause corrosion!
Chemical reactions of hydrocar$on can also causes corrosion!
9.0 O'er $e"in% !( 12@ +*e& " $e !,.
2n the shell and tu$e heat exchaner at the inlet =$ottom of the shell> hydrocar$on
is in li#uid state!
The inlet temperature of hydrocar$on is -':Vc! out let temperature is --9Vc!
The heatin fluid hot oil called Therminol passess throuh the tu$es! The inlet of hot
oil is at top of the $undle and outlet is at the $ottom The inlet temperature of the hot oil is *-0
Vc! and the outlet temperature is -:0Vc! 2f there is any o$struction or processin delay in the
production line it causes the shortae of hydrocar$on supplay in to the heat exchaner! .urin
"hen the hot oil "ill $e pass throuh the tu$es this converts the top hydrocar$on in $undle to
vapour state! 2n the vapour state convective heat transfer =h> is less! This causes the top '-0
u$e $ecome overheat!
CHAPTER-> TYPE
OF FAILURE
>.1T+*e *r"c?in%
The corrosion and erosion in the tu$e can cause tu$e $rakeae
>.2Fr"c+re in $e /e-d ,!ri!n
The clearance $et"een the shell and tu$e $undle can cause vi$ration in the tu$e
$undle! This cause the fracture formation in the tu$e sheet!
>.0T+*e *endin%
The clearance $et"een the shell and tu$e and over heatin can cause the $endin of
tu$es!
CHAPTER-J CHECIING THE
DESIGN
1. C!n&r+ci!n"- de"i-&
2nside diameter of the tu$e Jdr
Thickness of the tu$e
Out side diameter of the tu$e JdoJ
2n side diameter of the shell
3um$er of the tu$es
3um$er of the pass
2. De"i-& !( $! !i-
.ynamic viscosity
.ensity
Thermal conductivity
&pecific heat
0. De"i-& !(
"r!."ic
$Adr!c"r*!n&
.ynamic
viscosity
.ensity
Thermal conductivity &pecific heat
'4!,*mm
4!--mm
'9!05mmJ
9*4mm
*+0
+
0!-centi poise
-0K'06
4
3&G9
-
0!,0:kGm
*
0!095kcalGhnnVc
0!''0,"GmVc
*!*5',k0GkVc
0!9*centi poise
9*K'06
4
3&G9
-
0!,-0kGm*
0!'kcalGhrmVc
0!''+:"GmVc
-!*5+k0GkVc
8. Len%$ !( $e +*e
5verae lenth of the tu$e
9. O,er"in% c!ndii!n&
9ass flo" rate of hot oil JmhJ
One time oil passes '-0 tu$es 9ass flo" rate
of aromatic hydro car$ons Jmc6 2nlet temperature
of hot oil JThiJ
R-40,'0-G*+0
R++,9mm
R+!+,9mm
R++':*kGhr
)++':*G*+00K'-0
R0!'5*kGsec
R+4:0, kGhr R
':!9,kGsec
R*-0Vc
Out let temperature of hot oil JthoK R-:0Vc
2nlet temperature of aromatic hydro car$ons JTc0J R-':Vc
Outlet temperature of aromatic hydro car$ons JTcoJ R-*0Vc
>. C"-c+-"i!n
Lo mean temperature differenceR = 4 Tl ) 4T->Gln = 5T'G5T->
*:
%o" noHTWR3%adiusR%.evelop lenth8l -+4:!++'49!58--+!
:*+--9!*8*-+9,!4+*09!'84-5'-*!,+*,,!9856 -5'49!-+4++!:8+-5':4!++54
,!58:-4-00++-,!*8,-4--5!4+:0!,89-5-50!,+:,:!98'0-5-:+!-+,+:!:8l l -
4*0'!++94:!58'--**-::0-:!58'*-'*5-!4:'0:!,8'4',*::!,:',+!58'5'440
*!-:-++!:8'+94-,!+:*4+!5Total HTWR*+0Total lenthR-40,'0-mm
Ta$le)- Lenth of the tu$e
S 5
T'
5T-
L9T.
The multi pass cross flo" heat exchaner1 L9T.
Correction factor J7K find from heat transfer data $ook usin
Temperature ratio J?J and Capacity ratio J%J
Temperature ratio J?JR =%ise in temperature of the cold fluid> G
=.ifference in inlet temperature of the t"o fluids>
? R =TC%)Tci>G =T1%) Tc i > R
=-*0)-':>G =*-0)-':>
)0!'-+
Capacity ratio J%JR =Temperature drop of hot
7luid> G =Temperature drop of cold fluid>
% ) =Tho)Th0>G =Tco)Tci> R
=*-0)-:0>G=-*0)-':> R
*!,
Correction factor from data $ook chart R' L9T.
R'K+,!,: R+9!,:Vc
A .c!n&ider (-!/ in&ide $e +*e
9ass flo" rate of hot oil inside the tu$e 6mhJR0!'5*kGsec
%eynolds num$er J%eJ
R =4K rrih> G =*!'4Kdi Kdynamic viscosity> R
=4K0!'5*>G =*!'4K0!0'4,*K-0K '0 X
+5:,!-,
%eynolds num$er J%eJ reater than -*00 so flo" is tur$ulent
*,
2n the case of tur$ulent flo" 3usset num$er 63uJ
R 0!0-*,K%e
0,
?r
04
?randtl num$er J?rJ
R =dynamic viscosityKspecific heat>G =thermal conductivity
of hot oil>
R =-0K'06
4
,*!*',K'0
*
>G0!H0, R
59!,9
3u R 0!0-*K+5:'!-,
0,
K59!,9
0 4
R'*,!9
Convective heat transfer coefficient JhiJR =3uKk>Gdi
R ='*,!+9K0!''0,>G0!0'4,*
R '0*+!-"Gm
-
k
B. C!n&ider (-!/ !'er $e +*e
The flo" over the tu$e due to natural convection
?randtl num$er J?rJ
R =dynamic viscosityKspecific heat>G =thermal conductivity of
aromatic hydro car$ons>
R =*K '06
4
K-!*5+K'0
*
>G0!''+:
R ',,!'*
Frashof num$er JFr R =L
*
=* t>4v
-
Fr R =+!0,9
*
K0!00':+K9!,' K:'!5>G= ''!*4K'0J
*>-
R-!,:,K'0
+
/here
Lenth of the tu$e JLJR+!+,9m =*
R volumetric expansionRlGT R 'G
=-95L-:*> R '!:+0K '06
*
k6J
*9
FrK?r R -!,:K'0
+
K ',,!', R
0!5*9K'0
9
3u R 0!5*=FrK?r>
'G4
for ='0
4
Y FrK?r('0
9
>
R0!5*=0!5*9K'0
9
K',,!',>
0-5
R,:!4-
3uRh0d0Gk
h0 R=,:!4-K0!''+>G ='9!05K'0X
*
>
R494!:4"Gm
-
k
O'er"-- H.T c!e((icien
J2f R'G ==doG =diKhi>> L ==doG-k> 2n =doGdi>> L ='Gho>>
R 'G ==0!0'95G =0!0'4,*K'0*+!4>> L ==0!0'905G-K'*!+> 2n =0!0'905G0!0'4,*>> L
='G494!:-4>>
R-90!0599"Gm
-o
c
He" r"n&(er r"e c!-d (-+id
H Rmc cpc =Tco)Tci>
/here mc R':!9,kGsec Cpc
R-!*5+k0Gkoc T
R-':Vc
H R':!9,K-!*5+K'0 *K=-*0)-':> R
5505-'!-,"
40
He" r"n&(er r"e $! (-+id
H R mh cph =Th0)Thi>
/here mh R0!'5*kGsec
Cph R*!*',k0GkVc
Tco R*-0Vc
H R 0!'5*K*!*',K'0
*
K=*-0)-:0> Tci R-:0Vc
H R'-0K-5*,-!:!:" =one pass has '-0 tu$es>
R *0459-4"
H R8K 5K L9T.
5 RHG =8KL9T.>
5rea re#uired for the heat transfer R *0459-4G =-9005K+9!,:> R '50!'m
-
5ctual area R*!'4KdoKL
R*!'4K!0'905K+!+,9K*+0
R '44!040m
-
5ctual area R'44!040m
-

K'0*ZR'4,!*+ Ac+"- "re" K "re" reL+ired (!r $e $e"
r"n&(er S! de&i%n i& n! &"(e
CHAPTERS C-PROGRAMING OF
DESIGN
[includeYstdio!h(
[includeYconio!h(
[includeYmath!h(
void main=>
{
dou$le r31n3l1n3-1p3l1p3-13@
GG%eylolds 3um$er1 3usselt 3um$er ' \-1 ?randtl 3um$er '\-1 Frashoff 3um$er1 dou$le
pR01rR0@
dou$le iTHO@ GK 2nlet temperature of hot oil Thi =*-0 .eree C>KG
dou$le oTHO@ GK Outlet temperature of hot oil Tho =-:0 .eree C>KG
dou$le mTHO@GK9ean Temperature of Hot OilKG
dou$le iTCO@ GK 2nlet temperature of Cold oil Tci =-': .eree C>KG
dou$le oTCO@ GK Outlet temperature of Cold oil Tco =-*0 .eree C>KG
dou$le mTCO@GK9ean Temperature of Cold OilKG
dou$le i.T @ GK 2nside diameter of the tu$e R '4!,*mm KG
dou$le o.T@ GK Outside diameter of the tu$e R'9!05mm KG
dou$le nT@ GK 3um$er of the tu$es R *+0 KG
dou$le pass@ GK 3um$er of the pass R +KG
dou$le m7%?HO@GK 9ass flo" rate of hot oil R++':*k per hrKG
dou$le m7%&HO@ GK 9ass 7lo" %ate of Hot Oil ?er &econd throuh ' tu$e R 0!'5*
kGsecKG
dou$le m7%5HC@GK 9ass flo" rate of 5romatic Hydro Car$on R +4:0, kGhr KG dou$le
m7%?&5HC@ GK 9ass 7lo" %ate of 5romatic Hydro Car$on &econd R ':!9,
kJsecKG
dou$le dAHO@GK .ynamic viscosity hot oil R0!-centi poise R-0K'0)4 3sGm-KG dou$le
dHO@ GK .ensity hot oil R0!,0:kGm*KG
4'
dou$le tCHO@ GK Thermal conductivity hot oil R0!095kcalGhrm]c R0!''0,"GmocKG dou$le
sHHO@ GK&pecific heat hot oil R *!*5',k0Gkoc KG
dou$le dA5HCR9*K!000'@ GK.ynamic viscosity aromatic hydrocar$ons R0!9*centi poiseKG
R9*K'0)4 3&G9-KG
dou$le kA5HC@GK;inamatic Aiscosity of 5romatic Hydrocar$onKG dou$le d5HC R
0!,-0@GK.ensity aromatic hydrocar$onsR0!,-0kGm*KG dou$le tC5HC R 0!''+:@GK Thermal
conductivity aromatic hydrocar$ons R0!' kcalGhrmoc R 0!''+:"Gmoc KG
dou$le tCTR '*!*@GK Thermal conductivity of the tu$e materialR'*!*"GmkKG
dou$le sH5HCR-!*5+@ GK&pecific heat aromatic hydrocar$ons R-!*5+k0GkocKG
dou$le aLTR0@ GK 5verae Lenth of Tu$e KG
dou$le '9T.R0@ GG Lo 9ean Temperature .ifferenceGG
dou$le T'1T-R0@
dou$le hTC21hTCOR0@GKHeat Teanfer Coefficient at 2nlet and OutletKG dou$le
oHTCR0@ GGOverall Heat Transfer Co)efficientGG dou$le hT%HOR0@ GGHeat
Transfer %ate of Hot OilGG dou$le areaR0@ GG 5ctual 5rea of Tu$eGG dou$le
areaTh R 0@ GGTheoretical 5rea of Tu$eGG
clrscr=>@
GGinputtin values
printf=6Bnlnlet temperature of hot oil Thi in deree celciusI6>@
scanf=6ZlfJ1\iTHO>@
printf=6BnOutlet temperature of hot oil Tho in deree celciusI6>@
scanf=6ZlfJ1\oTHO>@
mTHOR=iTHOLoTHO>G-!0@
printf=6Bnlnlet temperature of Cold oil Tciin deree celciusI6>@
scanf=6ZlfJ1\iTCO>@
printf=6BnOutlet temperature of Cold oil Tco i n deree celciusI6>@
scanf=6ZlfJ1\oTCO>@
mTCOR=iTCOLoTCO>G-!0@
printf=6Bnlnside diameter of the tu$e in meterI6>@
scanf=6ZlfJ1\i.T>@
printf=6BnOutside diameter of the tu$e in meterI6>@
scanf=6ZlfJ1\o.T>@
printf=6Bn3um$er of the tu$esI6>@
scanf=6ZlfJ1\nT>@
printf=6Bn3um$er of the passI6>@
scanf=6ZlfJ1\pass>@
printf=6Bn9ass flo" rate of hot oil in kGhrI6>@
scanf=6Zlf 1\m7%?HO>@
m7%&HO R=m7%?HO>G=*+00!0K '-0!0>@ GK 9ass 7lo" %ate of Hot Oil ?er &econd throuh
' tu$e R 0!'5* kJsecKG
printf=6Bn9ass flo" rate of 5romatic Hydro Car$on kGhrI6>@
scanf=6ZlfJ1\m7%5HC>@
m7%?&5HC R=m7%5HC>G=*+00!0>@ GK 9ass 7lo" %ate of 5romatic Hydro Car$on &econd
R ':!9, kGsecKG
printf=6Bn.ynamic viscosity hot oil in centi poisI6>@
scanf=6ZlfJ1\dAHO>@
4-
dAHO R dAHOK0!0'@
printf=6Bn.ensity hot oil in kGm
5
*I6>@
scanf=6ZlfJ1\dHO>@
printf=6BnThermal conductivity hot oil in "GrakI6>@
scanf=6ZlfJ1\tCHO>@
printf=6Bn&pecific heat hot oil in 0Gk kI6>@ scanf=6Zlf
1\sHHO>@
printf=6Bn.ensity aromatic hydrocar$ons kGJm
5
*I6>@
scanf=6ZlfJ1\d5HC>@
printf=6BnThermal conductivity aromatic hydrocar$ons "GmkI6>@ scanf=6ZlfJ1\tC5HC>@
printf=6BnThermal conductivity of the tu$e material "GmkI6>@ scanf=6ZlfJ1\tCT>@
printf=6Bn&pecific heat aromatic hydrocar$ons 0Gk kI6>@
scanf=6ZlfJ1\sH5HC>@
printf=6Bndynamic viscosity of aromatic hydrocar$on in 3&Gm
5
-I6>@
scanf=6ZlfJ1\dA5HC>@
printf=6Bn5verae Lenth of Tu$e in meterI6>@
scanf=6ZlfJ1\aLT>@
TlRiTHO)oTCO@
T-RoTHO)iTCO@
l9T.R=Tl)T->G=lo=TlGT->>@
pR=oTCO)iTCO>G=oTHO)iTCO>@
rR=oTHO)iTCO>G=oTCO)iTCO>@
printf=6Zlf ZlfBt61p1r>@
r3R=4Km7%&HO>G=*!'4Ki.TKdAHO>@
printf=6%eynolds 3um$er RZlfBt61r3>@ if=r3(-*00>
/
p3l)=dAHOKsHHO!>G=tCHO>@ printf=6?randtl 3um$er lR
ZlfBt61p3l>@
n3 ' )0!0-* ,K=po"=r310!,>>K=po"=p3 '10!4>>@ printf=63usselt
3um$er lRZlfBt61n3l>@
printf=62nner .iameter of Tu$e R Zlf Thermal conductivity hot oil RZlf
Bt61i.T1tCHO>@
hTC2R=n3lKtCHO>Gi.T@
printf=6Heat Transfer Coefficient at 2nlet RZlfBt61hTC2>@
2
p3-R=dA5HCKsH5HC>G=tC5HC>@ printf=6?randtl
3um$er -RZlfBt61p3->@
mTHOR=iTHOLoTHO>G-@
mTCOR=iTCOLoTCO>G-@
kA5HCRdA5HCGd5HC@
printf=6 5verae Lenth of Tu$e RZlfBt 9ean Temperature of Hot Oil RZlfBt 9ean
Temperature of Cold Oil RZlfBt61aLT1mTHO1mTCO>@
3R=po"=aLT1*>K= ' G=mTHOL-:*>>K9!,' K=mTHO)mTCO>>G=po"=kA5HC1->>@
printffFrashoff 3um$er R ZlfBt613>@
if==3Kp3->YRpo"=l 019>>
\
n3-R0!5*Kpo"=3Kp3-10!-5>@
printf=63usselt 3um$er - RZlfBt61n3->@
2
else
^
4*
n3-R0!'*Kpo"=3Kp3-10!**>@
printf=63usselt 3um$er - RZlfBt61n3->@
i
i
printf=6?roduct of Frashoff 3um$er and ?randtl 3um$er - R ZlfBt613Kp3->@
hTCOR=n3-KtC5HC>Go.T@
printf=6Heat Transfer Coefficient at Outlet RZlfBt61hTCO>@
oHTCR'!0G==o.TG=i.TKhTC2>>L==o.TG=-!0KtCT>>Klo=o.TGi.T>>L=L0GhTCO>>@
printf=6Overall Heat Transfer Coefficient RZlfBt61oHTC>@
hT%HORm7%&HOKsHHOK=iTHO)oTHO>K'-0@
printf=6Heat Transfer %ate of Hot Oil RZlfBt61hT%HO>@
printf=6Lo 9ean Temperature .ifference RZlfBt61l9T.>@
areaR *!'4 Ko.TKaLTK*+0@
area R areaK '!0*@ GGl 0*Z of Theoretical 5rea is found to compare "ith 5ctual 5reaGG
printf=65ctual 5rea R ZlfBt61 area>@ areaTh RhT%HOG=oHTCKl9T.>@ printf=6Bn Thearetical
5rea RZlf J1areaTh>@ i f= areaThYRarea>
{
printf=6Bn.esin is &afe6>@ G
else
^
printf=6Bn.esin is 3ot &afe6>@
i
etch=>@
OUT PUT USING STAINLESS STEEL
INPUT
2nlet temperature of hot oil Thi in deree celciusI*-0
Outlet temperature of hot oil Tho in deree celciusI-:0
2nlet temperature of Cold oil Tciin deree celciusI-':
Outlet temperature of Cold oil Tco in deree celciusI-*0
2nside diameter of the tu$e in meterI0!0'4,*
Outside diameter of the tu$e in meterI0!0'905
3um$er of the tu$esI*+0
3um$er of the passI+
9ass flo" rate of hot oil in kGhrI++':*
9ass flo" rate of 5romatic Hydro Car$on kGhrI+4:0,
.ynamic viscosity hot oil in centi poisI0!-
.ensity hot oil in kGm
5
*I0!,0:
Thermal conductivity hot oil in "GmkI0!''0,
&pecific heat hot oil in 0Gk kI**',
.ensity aromatic hydrocar$ons kGm
5
*I0!,-
Thermal conductivity aromatic hydrocar$ons "GmkI0!''+:
Thermal conductivity of the tu$e material "GmkI'*!+
&pecific heat aromatic hydrocar$ons 0Gk kI -*5+
44
dynamic viscosity of aromatic hydrocar$on in 3)&Gm
-
I0!009*
5verae Lenth of Tu$e in meterI +!+,:
OUT PUT
%eynolds 3um$er R +5:,!945-:5
?randtl 3um$er 'R59!,9'+9:
3usselt 3um$er 'R'*,!+9'''0
2nner diameter of tu$e R0!0'4,*0
Thermal conductivity hot oil R0!''0,00
Heat Transfer Coefficient at 2nlet R'0*+!-0,+95
?randtl 3um$er- )',:!:5*-'*
5verae Lenth of Tu$e in meter R+!+,:000 !!
9ean Temperature of Hot Oil R-95!000000
9ean Temperature of Cold Oil R--*!500000
Frashoffnum$erR-,:0++4!,44-,+
3usselt 3um$er-R,0!:54:9,
?roduct of Frashoff 3um$er and ?randtl 3um$er -
R5*,9:+549!0'+'+9
Heat Transfer Coefficient at Outlet R494!:0-+-*
Overall Heat Transfer Co)efficient R-90!99+-5-
Heat Transfer %ate of Hot OilR*0494:-!4'+++:
Lo mean temperature differenceR+9!,:4,99
5ctual areaR '4,!0*
Theoretical area)'49!9:4050
.esin is 3ot &afe
OUT PUT USING INCOLOY
INPUT
2nlet temperature of hot oil Thi in deree celciusI*-0
Outlet temperature of hot oil Tho in deree celciusI-:0
2nlet temperature of Cold oil Tciin deree celciusI-':
Outlet temperature of Cold oil Tco in deree celciusI-*0
2nside diameter of the tu$e in meterI0!0T4,*
Outside diameter of the tu$e in meterI0!0'905
3um$er of the tu$esI* +0
3um$er of the passI+
9ass flo" rate of hot oil in kGhrI++':*
9ass flo" rate of 5romatic Hydro Car$on kGhrI+4:0,
.ynamic viscosity hot oil in centi poisI0!-
.ensity hot oil in kGm
5
*I0!,0:
Thermal conductivity hot oil in "GmkI0!''0,
&pecific heat hot oil in 0Gk kI**',
.ensity aromatic hydrocar$ons kGm
5
*I0!,-
Thermal conductivity aromatic hydrocar$ons "GmkI0!''+:
Thermal conductivity of the tu$e material "GmkI'9!+
&pecific heat aromatic hydrocar$ons 0Gk kI-*5+
dynamic viscosity of aromatic hydrocar$on in 3&Gm
5
-I0!009*
45
5verae Lenth of Tu$e in meterI+!+,:
OUT PUT
%eynolds 3um$er R+5:,!945-:5
?randtl 3um$er' R59!,9'+9:
3usselt 3um$er ' R'*,!+9'''0
2nner diameter of tu$e R0!0'4,*0
Thermal conductivity hot oil R0!''0,00
Heat Transfer Coefficient at 2nlet R'0*+!-0,+95
?randtl 3um$er- R',:!:5*-'*
5verae Lenth of Tu$e in meter R+!+,:000
9ean Temperature of Hot Oil R-95!000000
9ean Temperature of Cold Oil R--*!500000
Frashoff num$er R-,:0++4!,44-,+
3usselt 3um$er-R,0!:54:9,
?roduct of Frashoff 3um$er and ?randtl 3um$er -
R5*,9:+549!0'+'+9 Heat Transfer Coefficient at Outlet
R494!:0-+-* Overall Heat Transfer Co)efficient R-95!+'4+,,
Heat Transfer %ate of Hot Oil R*0494:-!4'+++: Lo mean
temperature difference R+9!,:4,99 5ctual areaR '4,!0*
Theoretical areaR'4:!+*09,' .esin is &afe
CHAPTER-M REMEDY FOR FAILURE M.1
REPLACE THE TUBES BY USING INCOLOY TUBES
%eplace the stainless steels tu$e usin incoloy tu$es the chance failiure is less 1the
thermal conductivity of the incloy is '9!+"Gmk $ut thermal conductivity of the stainless steels
is '*!+"Gmk so the heat transfer area re#uired is hih in this case around '*0m- $ut usin
incloy the heat transfer area re#uired is around '-:!5m- the actual heat transfer area is '-,m-
due to this reason usin incoloy decreases the chance of failure! The notes a$out incoloy
sho"n $elo"!
De&cri,i!n
5lloy ,00 is an iron)nickel)chromium alloy "ith moderate strenth and ood
resistance to oxidation and car$uri<ation at elevated temperatures! 2t is particularly useful for
hih)temperature e#uipment in the petrochemical industry $ecause the alloy doesnJt form the
em$rittlin sima phase after lon time exposure at '-00V7 =+49VC>! Excellent resistance to
chloride stress)corrosion crackin is another important feature of alloy ,00!
5lloy ,00H is a solution heat treated =-'00V7G''50VC>1 controlled)car$on version of
alloy ,00 "ith improved elevated temperature properties! 2t has improved creep and stress)
rupture characteristics in the ''00V7 =59*VC> to ',00V7 =9,-VC> temperature rane! 2ncoloy
alloy steel containin +Z moly$denum and "ith properties enhanced $y its content of
4+
nitroen 2ts hih content of nickel results in thermal sta$ility and resistance to stress corrosion
crackin
2ncoloy 2ncoloy ,00
Element 9in 9ax
3ickel L Co$alt *0!0 *0!0
Co$alt -!00
Chromium '9!0 -*!0
Copper 0!:5
2ron Eal
&ilicon '!00
9ananese '!50
Mec$"nic"- Pr!,erie&
23COLOW alloy offers hiher strenth than conventional austenitic stainless steels
and typical of other superaustenitic stainless steels! Even "ith its hih level of strenth1 the
alloy offers excellent ductility for enhanced forma$ility
C!rr!&i!n Re&i&"nce
23COLOW alloy offers resistance to many modes of attack in a variety of aressive
environments! 2t is especially resistant to locali<ed attack =crevice and pittin corrosion> in
acid G halide media! 5lloy also resists micro$ially induced corrosion! /ith -5Z nickel1 the
alloy is much more resistant to chloride)induced stress corrosion crackin than austenitic
stainless steels =52&2 *00 rades>!5nnealin after fa$rication can also have a positive
influence on the corrosion resistance of "elded components!
Micr!&r+c+re
5lloy exhi$its a fully austenitic structure! Themicrostructure is especially 6clean6 due
to proprietarydeoxidation practices durin meltin! Thus1 $andin and triners in alloy
products are minimi<ed!
A,,-ic"i!n
Typical applications for alloy ,00 and ,00H are ) Heat exchaners and process pipin@
car$uri<in fixtures and retorts@ furnace components@ electric rane heatin)element
sheathin@ extruded tu$in for ethylene and steam methane reformin furnaces@ ammonia
effluent coolers!
P$A&ic"- ,r!,erie& !( inc!-!A
.ensi tyR:!95 Gcm* Thermal Conductivity)
'9!+ /:m); .ynamic 9odulus of Elasticity)
'9+ F?a Electrical %esistivity)'!': microhm)
m
4:
Car$onQ
0!'05luminum0!'50!+0Titanium0!'50!+0&ulfur
Q0!0'5
Ta$le)* contents in incoloy
CALCULATION USING INCOLOY IN TUBE MATERIAL He"
r"n&(er r"e $! (-+id
H R mh Cph =Tho)Thi>
/here mh )0!'5*kGsec Cph
R*!*',k0GkVc Tco
R*-0Vc
H R 0!'5*K*!*',K'0
*
K=*-0)-:0> Tci R-:0Vc
H R'-0K-5*,-!:!:" =one pass has '-0 tu$es> R *0459-4"
H R8 5 L9T.
O'er"-- H.T c!e((icien
J8J R'G ==doG =diKhi>> L ==doG-k> 2n =doGdi>> L ='Gho>>
R 'G ==0!0'95G =0!0'4,*K'0*+!4>> L ==0!0'905G-K'9!+> 2n
=0!0'905G0!0'4,*>> L
='G494!:-4>>
R-95!+"Gm
-
V
5 )HG =8KL9T.>
5rea re#uired for the heat transfer R *0459-4G =-95!+K+9!,:>
)'4:!+:m
-
5ctual area R*!'4KdoKL
)*!'4K!0'905K+!+,9K*+0
)'44!040m
-
5ctual area
)'44!040m
-
K'0*ZR'4,!*+
Ac+"- "re" N "re" reL+ired (!r $e $e" r"n&(er
.ue to this reason +&in% inc!-!A in tu$e material desin is safe
c!ndii!n n!)- c!ndii!n n! )2
' !usin steel as tu$e material ' !usin incoly as tu$e material
-!theramal conductivity Jk
1R
T*!+"Gmk -! thermal conductivity JkJR'9!+"Gmk
*! area re#uired for the heat transfer *! area re#uired for the heat transfer
R '50!'m
-
R '4:!+m
-
4! 5ctual area isR '4,!*+m
-
1 so desin 4 5ctual area is R '4,!*+m
-
1 so desin is
is note safe safe
T"*-e-8 c!.*"ri&!n /i$ &"in-e&& &ee- "nd inc!-!A
M.2 CHANGE THE OIL FLO< DIRECTION
2n this remedy chane the hot oil flo" direction !2n existin condition hot oil iven in
top of the tu$e $ut in this condition hot oil iven in $ottom of the tu$e
Fir& c!n&ider $e e#i&in% c!ndii!n
4,
This is the existin hot oil direction in HOC! 2n this condition the hot oil iven at top
of the tu$e! 5nd in this condition temperature difference of the top side is hih! 2n top side of
the shell and tu$e heat exchaner is vapor the convective heat transfer coefficient of the vapor
is less due to this reason heat transfer rate is less and over heatin the top '-0 tu$es !7iure
sho" the arranement of this condition
49
5ro
xaJic a

hviirc
c)
ar$oJi
Temperature difference in the top side
5 T R Hot oil inlet) 5romatic hydrocar$on at out let R*-0)--9R9'Vc The heat transfer H R
h5 5T
O;P $:A:M1
+
c
F1=
Temperature difference in the $ottom side
R Hot oil outlet) 5romatic hydrocar$on at inlet
)-:0)-'9R5 Tc
Sec!nd-A c!n&ider $e c$"n%in% c!ndii!n
2n this condition chane the hot oil direction that means hot oil iven at $ottom side
of the tu$e1 due to this reason the temperature difference in the top side is decreased $ut the
temperature difference in the $ottom side is increased !The $ottom side the aromatic
hydrocar$on in the form of li#uid 1 the convective heat transfer coefficient of the li#uid is
hih due to this reason hih temperature difference in the $ottom side not effect the tu$e!
7iure sho" the arranement of this condition
,
Temperature difference in the top side
R Hot oil out let) 5romatic hydrocar$on at out let
R-:0)--9R4 f c
O2P $:AK4rc
F2=
Temperature difference in the $ottom side
R Hot oil in let) 5romatic hydrocar$on at inlet
R*-0)-'9R' OTc
,
5rom
atic
i;itsi
at
--&sc
5ronatic
hydrocar
$on
60K
H0
2n e#uation ='> \ =-> convective heat transfer coeficient JhJ and surface area J5J are
same !'
st
case chance of over heatin of the tu$e is hih $ecause the '
st
case temperature
difference in the top side is 9'Vc $ut in the -
nd
case the temperature difference is only 4'Vc so
the second case no chance of over heatin
M.0 USE IETTLE TYPE HEAT EXCHANGER
&hell and tu$e heat exchaners are amon the most "idely used types of heat
exchaners! Aarious shell and tu$e heat exchaners are desined for vapour eneration on the
shell side! They are "idely applied in chemical1 process1 and enery po"er industry1 in
7iure)'5 kettle type heat exchaner
condition noIlcondition no I-' !hot oil inlet at top side
-! Temperature difference in the top side
)Hot oil
inlet) 5romatic hydrocar$on at out let R*-0)-*0R90Vc
*! Temperature difference in the $ottom
side
R Hot oil
outlet) 5romatic hydrocar$on at inlet R-:0)-':R5*Vc
4! temperature difference in the topside
is hih so over heat the top '-0 tu$es
5! temperature difference in the $ottom
side is less' !hot oil inlet at $ottom side
-! Temperature difference in the top side
RHot oil out let) 5romatic hydrocar$on at out let R-:0)-* 0R40Vc
*! Temperature difference in the $ottom
side
R Hot oil
in let) 5romatic hydrocar$on at inlet R*-0)-':R'0*Vc
4! temperature difference in the top is
small
5! temperature difference in the $ottom
side is hih !The $ottom side aromatic
hydro car$on in the form of li#uid so this
temperature difference not effect the tu$e
Ta$le)5 Comparison of existin condition \ chanin condition
Tu$e Tu$e Aapour outlet to
plate supports
coll
OJ
nn
8)
tu$es
2 2 '( '
Li#uid feed from Eottom
product
column
refreirations and air)conditionin e#uipments1 and they are applied such as re$oilers1 steam
enerators1 and evaporators! 2t has $een estimated that more than 50Z of all heat exchaners
employed in process industries are used to $oil fluids and involvet"o)phase flo" on the shell
side _'C! 2n process industry they are kno"n as re$oilers1"hile kettle re$oilers are one of the
most com mon re$oiler types _-C! 5lso1 some developments of hori<ontal steam enerators for
nuclear po"er plants are $ased on the kettle re$oiler desin _*C! 5 typical desin of the kettle
re$oiler applied in the process industry is sho"n in fi! '! The evaporatin fluid flo"s on the
shell side1 across a hori<ontal tu$e $undle! The heat is transferred to the $oilin t"o)phase
mixture from a hot fluid that circulates inside the tu$es! The li#uid level is controlled $y a
"eir1 so that the $undle is al"ays su$mered in li#uid! The ap $et"een the $undle and the
shell allo"s internal recirculation of li#uid !The li#uid enters the $undle at its $ottom only!
The mass velocity of fluid across the $undle is increased $y the recirculation of li#uid1
affectin the lo$al heat transfer coeffiient!
M.8 PRE7ENT 7IBRATION BY USING DTS STRIP
.T& Technoloy consists of dimpled and corruated straiht metal strips that are
inserted into a heat exchaner $undle to reduce vi$ration $y stiffenin the $undle1as sho"n in
fiure 1the corruations on each strip act as a "ede to slihtly deflect the tu$es The dimples
on each end of each thin strip provide a lockin mechanism to hold the strip in place
.T& &trip 2nstalled in Eundle 7iure)'+ .T& strip
CHAPTER-1@
CONCLUSION
'! Tar column re$oiler E4509 "as found failin in service and the cost of each
failure "as found sinificance as it can effect the production!
-! The one of exchaner tu$e "as found tried "ith &&)*'+ and incoloy ),-5
tu$in as per desin check found incoloy ,-5 as the only suita$le one !as the thermal
conductivity of incoloy ),-5's Considera$ly hiher than of &&)*'+!
*! The vi$ration of tu$e are also found tu$e season of failure "hich can $e
prevented $y installation of .T& strip in $et"een tu$es
4! Chane in hot oil inlet and out let position or the direction of flo" of hot oil
also can ive results as their "ill $e marinal decrease in "all temperature of tu$e!
5! chane in desin to a kettle type re$oiler also can improve the life of the
exchaner as the tu$e $undle "ill $e immersed fully in li#uid durin operation their
$y reducin all temperature !
Therefore it is recommended that the tu$e $undle shell $e made in incoloy ,-5 tu$e
$undle made "ith .T& strip and modify shell to a kettle type exchaner!
CHAPTER-11
REFERENCES
'! Heat and 9ass Trans!fer)%!;!%a0 put
-! Heat and 9ass Transfer)9ahesh !9! %athore
*! ?erryJs chemical enineerin data $ook
4! Heat and 9ass Transfer)p!;!3a
5! Heat and 9ass Transfer data $ook).om kund"ar
+! """!hocl!com