Section 18

Heat Exchangers
GENERAL
A heat exchanger or interchanger is a device which transfers heat from one fluid to another
through a container wall. In a typical process industry application, a heat exchanger may be a
vessel in which an outgoing processed hot liquid transfers some of its heat to an incoming cold
liquid about to be processed. The amount of heat transferred is therefore not lost and can be
used again.
Heat exchangers can also be used to cool process fluids. For example, an outgoing cold gas
may take up part of the heat from an incoming warmer gas, as in a liquid-air plant.

Double Pipe Exchangers

As shown in Figure 18-1, a double pipe or fintube exchanger consists of two pipes, one inside
another. The inner tube is usually finned to provide a larger surface for heat transfer. Double
pipe exchangers are used where flow and necessary temperature transfer are rather small.

1. SHELL ASSEMBLY 8. FINTUBE STUB END FLANGE 15. SHELL NOZZLE BOLTING 16.
2. TUBE ASSEMBLY 9. TUBE RETURN BEND CONNECTOR 17. BRACKET BOLTS
3. COVER PLATE 10. TUBE RETURN BEND CONNECTOR 18. COVER GASKET
4. COMPRESSION FLANGE 11. TUBE RETURN BEND CONNECTOR 19. FINTUBE GASKET
5. SEALING RING 12. SHELL NOZZLE COMPANION FLANGE 20. SHELL NOZZLE GASKET
6. SPLIT RING 13. COVER PLATE BOLTING 21. NAMEPLATE
7. FINTUBE FITTING FLANGE 14. TUBESIDE BOLTING

FIGURE 18- - DOUBLE PIPE EXCHANGER

Fintube exchangers are generally used when one fluid is gaseous, viscous, or of small quantity.
They are particularly desirable for high pressure services because their small diameter is
conducive to low cost construction. Their modular design assures maximum flexibility of
application since sections can be stacked vertically or horizontally to attain desired heat transfer.
It is also easy to reuse these units in other services since one or more sections may be used as
needed. The fins can be welded to the tube to form a unit. Fins can also be formed by an
extrusion process. For special applications they may be on the inside or on both inside and
outside of the parent pipe.

© 1996 Bechtel Corp. Piping/Mechanical Handbook 18-1

Section 18 Heat Exchangers
FIGURE 18- - TEMA SHELL AND TUBE EXCHANGER TYPES

18-2 Piping/Mechanical Handbook 1996:Rev.2

 Heat Exchangers Section 18

FIGURE 18- - TYPICAL SHELL AND TUBE HEAT EXCHANGER

1. PASS PARTITION 12. IMPINGEMENT BAFFLE 23. GASKET

2. BLIND FLANGE 13. TUBE 24. BACK-UP RING
3. LIFTING RING 14. TIE ROD 25. SPLIT-KEY RING
4. CHANNEL FLANGE 15. SPACER 26. VENT CONNECTION
5. CHANNEL CYLINDER 16. SHELL CYLINDER 27. SHELL COVER CYLINDER
6. CHANNEL NOZZLE 17. TRAVERSE BAFFLE 28. SHELL COVER HEAD
7. CHANNEL FLANGE 18. SUPPORT PLATE 29. FLOATING HEAD COVER
8. STATIONARY TUBE SHEET 19. STUD 30. FLOATING TUBE SHEET
9. SHELL FLANGE (CHANNEL END) 20. HEX NUT 31. DRAIN CONNECTION
10. INSTRUMENT CONNECTION 21. SHELL FLANGE (COVER END) 32. SUPPORT SADDLES
11. SHELL NOZZLE 22. SHELL COVER FLANGE

The shell side is furnished with companion flanges so that piping can be connected to a beveled
end. Tubeside connections are supplied with a flanged assembly to allow the tube hairpin to be
disconnected from the piping. The tube or hairpin section will be pulled from the return bend
housing end.
These units are almost always installed as multiple modules. They are normally spoken of in
multiples such as "3 wide by 2 high" which refers to 6 modules installed in 2 layers, 3 side by side
units. Support saddles are provided with bolt holes on all four sides for modular bolting and are
not fixed to the shell assembly, leaving foundation spacing. Sometimes one or two units are
bolted to vertical steel columns.

Shell and Tube Exchangers

Shell and tube type exchangers of the type shown in Figure 18-3 are most commonly specified
for process plants. These exchangers are designed in accordance with the TEMA (Tubular

1996:Rev.2 Piping/Mechanical Handbook 18-3

Section 18 Heat Exchangers

FIGURE 18- - TEMA TYPES AES SHELL AND TUBE EXCHANGER

Exchanger Manufacturers Association) code. Figure 18-2 lists typical TEMA shell and tube heat
exchanger types. TEMA also specifies exchanger part types in a letter code.
Referring to the type AES exchanger shown in Figure 18-4, flow entering the nozzle, Item 6, at
the channel or tubeside end meets the pass partition, Item 1, and is diverted into the tubes. The
tubes, Item 13, route flow to the other end and back to the channel outlet nozzle. Shell side fluid
enters nozzle, Item 11, and makes contact with the outside of the tubes. Transverse baffles, Item
17, are located so that they force the fluid to flow up and down, making the most efficient tube
contact and attaining maximum heat transfer on its way to the outlet nozzle.
The tube bundle is comprised of the tubesheet, Item 8, and the tubes attached to the tubesheet.
By removing the channel section, the entire tube bundle can be pulled out from the exchanger for
cleaning, repairs or total replacement. Not all exchangers have removable tube bundles.
Nonremovable tube bundle exchangers are called fixed tubesheet types.

18-4 Piping/Mechanical Handbook 1996:Rev.2

 Heat Exchangers Section 18

FIGURE 18- - TEMA KETTLE TYPE SHELL AND TUBE EXCHANGER

1. CHANNEL COVER 7. SHELL NOZZLE 13. SHELL FLANGE

2. CHANNEL FLANGE 8. LIQUID LEVEL CONNECTION 14. SUPPORT
3. INSTRUMENT CONNECTION 9. SHELL COVER 15. TIE RODS AND SPACERS
4. CHANNEL NOZZLE 10. WEIR 16. SUPPORT PLATES
5. PASS PARTITION 11. CHANNEL 17. TUBES
6. SHELL 12. TUBESHEET

Kettle Type Exhangers

In the kettle type exchanger shown in Figure 18-5, the heating fluid always enters the channel top
nozzle, Item 4, and exits via the bottom channel nozzle. The main purpose of the shell side is to
vaporize liquid entering the shell nozzle, Item 7, near the shell flange, Item 13. Vapor exits
through the shell nozzle, Item 7, at the top of the exchanger shell. The weir, Item 10, is a dam
designed to keep the tube bundle covered with liquid at all times. Surplus liquid overflows the
weir and into the shell cover area. A level controller is piped to the Liquid Level Connections, Item
8, and maintains liquid level in this section at about half the weir height. Surplus liquid exits via
the shell nozzle, Item 7, in this section. Normally a level gage allows visual examination of the
liquid level behind the weir.

1996:Rev.2 Piping/Mechanical Handbook 18-5

Section 18 Heat Exchangers

FIGURE 18- - INDUCED DRAFT AIR COOLED HEAT EXCHANGER

Air Cooled Heat Exchangers

Air cooled heat exchangers are those in which the cooling is done by blowing or drawing air
across finned tubes. Air cooled exchangers may be either induced draft as shown in Figure 18-6
or forced draft as shown in Figure 18-7 which means that the fans may either be mounted above
the tube sections, drawing the air up through the tubes and exhausting to the atmosphere, or the
fans may be mounted below the tube sections, drawing the air from the atmosphere and forcing it
up through the sections. The commodity temperature from the coolers can be controlled by:
· The use of two speed fans
· Adjustable louvers
· A combination of the two
Two speed fans have the definite advantage of conserving horsepower and are usually provided.
The range of control gained by this means is obviously limited and, for this reason, adjustable
louvers are quite often provided where more precise control is required such as in extremely cold
climates. The louvers may be manually or automatically controlled by the commodity outlet
temperature. The fans may also have adjustable pitch blades for further temperature control.
This is usually done automatically through a hydraulic drive.

18-6 Piping/Mechanical Handbook 1996:Rev.2

 Heat Exchangers Section 18

FIGURE 18- - FORCED DRAFT AIR COOLED HEAT EXCHANGER

A significant feature of the dry coolers is the finned tubes. It is necessary that the tubes have
these fins to increase the surface in contact with the air where the heat transfer rate is usually
quite low. Since these fins must be relied on to conduct the bulk of the heat from the commodity
inside the tubes to the air outside, it is important that they maintain a good thermal bond with the
tubes at all times.
There are several different types of fin construction. The best and most durable type is that in
which the fins are an integral part of the tube itself and are formed by extrusion of the tube
through a die. This type of tube, however, is usually rather expensive. At least one manufacturer
attaches the fins by routing a groove in the tube wall and forcing the fin tightly into this groove. In
some cases, the fin is wrapped around the tube and then soldered to the tube. This provides a
very high thermal efficiency. In some cases, the fins are wound in a tight helix about the tube and
soldered at each end. This design depends on pressure to hold the fin against the tube and air
gaps between the fin and tube reduce the thermal transfer.

1996:Rev.2 Piping/Mechanical Handbook 18-7