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Effective December 6, 2006, this report has been made publicly available in accordance
with Section 734.3(b)(3) and published in accordance with Section 734.7 of the U.S.
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INTEREST CATEGORIES
BACKGROUND A large number of heat exchangers are used in any power
Maintenance practices generating facility. Heat exchangers can be of various designs and construction.
Nuclear plant operation and The effect of inefficient heat exchangers can range from being a slow economic
drain on the generation facility to completely shutting it down. This Tech Note is
maintenance
intended to provide an overview of the basic operation and maintenance needs
Engineering and technical of heat exchangers.
support
Training
OBJECTIVES
KEYWORDS • To provide information on the operational and maintenance requirements of
various types of heat exchangers used in power plants
Maintenance • To provide guidance in eliminating common errors in heat exchanger mainte-
Heat exchangers nance and operation
Heat transfer
Performance monitoring APPROACH A scope of work was prepared with input from a number of utility
personnel familiar with the maintenance and operational requirements of heat
exchangers. Based on this input, a draft document was developed and submit-
ted for review to a number of utility personnel and an independent heat ex-
changer manufacturer and servicing organization. Their comments were evalu-
ated and incorporated in this final document.
TR-106741
Final Report
March 1997
Prepared by
Duke Engineering & Services
215 Shuman Boulevard, Suite 172
Naperville, IL 60563
Principal Investigator:
Robert A. Tatara, Ph.D.
Prepared for
Nuclear Maintenance Applications Center
1300 Harris Boulevard
Charlotte, North Carolina 28262
Operated by
Electric Power Research Institute
3412 Hillview Avenue
Palo Alto, California 94304
EPRI Project Manager
Vic Varma
Nuclear Power Group
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EPRI Licensed Material
Heat Exchangers: An Overview of Maintenance and Operations
ABSTRACT
ACKNOWLEDGMENTS
CONTENTS
2.10 Shutdown......................................................................................... 13
LIST OF FIGURES
LIST OF TABLES
1
INTRODUCTION
• Condensate
• Intercooler
• Aftercooler
• Feedwater heater
The Tubular Exchanger Manufacturers Association (TEMA) heat exchanger
nomenclature is used throughout and is presented in Figure 1.
E L
A Fixed Tubesheet
One Pass Shell Like “A” Stationary Head
Channel &
Removable Cover
F M
Fixed Tubesheet
Two Pass Shell Like “B” Stationary Head
With Longitudinal Baffle
B
N
G
Fixed Tubesheet
Like “N” Stationary Head
Bonnet (Integral Cover) Split Flow
P
H
C Removable
Tube
Outside Packed Floating Head
Bundle
Only Double Split Flow
S
Channel Integral With
Tubesheet & Removable Cover
J Floating Head
With Backing Device
Divided Flow
T
N
Pull Through Floating Head
K
Channel Integral With
Tubesheet & Removable Cover
U
Kettle-Type Reboiler
U-Tube Bundle
D
X
W
Externally Sealed
Special High Pressure Closure Cross Flow Floating Tubesheet
Figure 1
TEMA Heat Exchanger Nomenclature
(Source: Standards of the Tubular Exchanger Manufacturers Association. Tubular Exchanger
Manufacturers Association, Inc., Tarrytown, NY 1988. Reproduced with permission.)
Room coolers, plate heat exchangers, and other types of heat exchangers are
only briefly mentioned in this Tech Note. Operational and maintenance data
for these exchangers are either too specific in nature (room coolers) or lack
history in power plant applications (plate heat exchangers). Feedwater
heaters have been extensively documented elsewhere, and this Tech Note is
not a substitute for those documents. Feedwater heaters are treated in a
general fashion as any other shell-and-tube exchanger. Thus, issues unique to
a feedwater heater are outside the present scope of this document.
It is assumed that the reader of this Tech Note is experienced in the subject of
heat exchangers because the focus is hands-on practical experience data and
issue awareness. The reader must have enough subject knowledge to apply
the information on a case-by-case basis. Evaluate the generalized information
given here carefully before applying it to specific cases because heat ex-
changer designs and applications vary considerably even when restricted to
shell-and-tube units.
Thus, the intended audience is all personnel who are responsible for the
continued operation of power plant heat exchangers.
When appropriate, other documents and reports are referenced. They are
highly specific to subject areas, such as fouling or heat exchanger performance
monitoring, and are only briefly described here. Likewise, technical informa-
tion that exists in various codes and standards is not repeated here.
2
HEAT EXCHANGER PERFORMANCE
For startup, circulate the cold fluid first, then add the hot fluid slowly up to
2.1 Startup
the desired rate. Always look to minimize thermal differentials. This is
critical for feedwater heaters and other steam-condensing heat exchangers
where elevated steam temperatures are encountered. Multiple temperature
cycles are particularly dangerous unless the exchanger, as part of its fatigue
analysis, is designed to handle that number of cycles in its lifetime. Repeated
pressure cycles can also damage a heat exchanger, and these effects are
computed by the fatigue analysis. These analyses are required for the Ameri-
can Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code
Section III and Section VIII, Division 2 vessels only. Thus, additional care
must be taken when ASME Section VIII, Division 1 heat exchangers are
exposed to temperature or pressure cycling.
Special attention must be observed with a differential-pressure-designed
exchanger. In the vast majority of cases, a heat exchanger is designed for the
tubeside and shellside absolute pressures, independent of the other side. On
the other hand, a differential-pressure-designed exchanger is constructed to
withstand only the differential tubeside-to-shellside pressure. Therefore, in an
operation of this type, attention must be given to maintaining the correct
pressure on both the tubeside and the shellside. This holds true for startup and
shutdown as well as during operation. Instructions from the manufacturer are
the best source of data for the safe operation of this type of exchanger.
Partition
Weld Tubesheet
Gasket
Figure 2
Typical Pass Partition Modifications
can be a limiting factor. A slight gap is retained to avoid locking the tube in
the baffle plate. Although stresses are introduced, they are equal to or less
than at the tube-to-tubesheet joints. The increase in tubeside pressure drop,
due to expansion/contraction of the flow, is negligible.
Figure 3
Tube Failure Due to Impingement in a Component
Cooling Water Heat Exchanger
Another vibration indicator is fatigue failure of the tube near its tubesheet
joint. Tube movement hardens the tube material and increases its susceptibility
to stress cracking. Simultaneously, residual rolling stresses are reduced, weak-
ening the tube-to-tubesheet joint. If a welded joint is present, the weld is
damaged and the cracks can continue through the tube and into the tubesheet.
Excessive noise during operation indicates shellside vortex shedding caused
by the fluid turbulence produced as the flow crosses a tube. The vortices
occur near the backside of the tube. The sounds can be loud, very unpleas-
ant, and intolerable to personnel in the area. Collisions between tubes and
baffles can also be loud enough to be heard easily. Vortex shedding, turbu-
lence, and tube vibration consume momentum or energy from the shellside
flow. Thus, an increase in pressure drop can be measured on the shellside
when maintaining the design flow rate. This can point to vibration problems
if other causes for the additional pressure drop are eliminated.
There are several preventive steps available. First, shellside velocity should
be reduced because vibration susceptibility increases when the actual flow
rate is greater than twice the design level. It is beneficial to avoid vibration
from external sources, such as pumps, compressors, motors, control valve
cycling, or any other cause, that can be transmitted by the fluid, supports, or
piping to the heat exchanger.
At the inlet nozzle of the shellside, there is a high potential for vibration,
2.7 Shellside Inlet
Nozzle Flow erosion, and cavitation. If operation indicates vibration or if maintenance
locates tube damage in this region, several options exist. If excess thermal
capacity is present in the exchanger, then it is simple to just remove all the
tubes (and plug the tubesheet holes) in one or two rows at the inlet to increase
the area for the entering fluid. Alternatively, the susceptible tube rows are
replaced with heavy wall tubes or dummy rods at the inlet for two or three
rows (or columns). Of course, heat transfer area is lost in such a modification.
In a removable bundle, another method is to attach shields on the tubes in
the first two or three rows (or columns) at the inlet. It is possible to weld the
shields to the tubes. The shields need only span the length of the first baffle
spacing so that far less tube area is lost to heat transfer. Figure 4 provides an
example of shields in a tube bundle. The actual number and type of shields
vary with the application. One drawback is that the shield/tube interface is a
potential corrosion spot.
Shell
Flow
Tubes
Angle tube protectors
(protect against fluid impingement/erosion)
Figure 4
Tube Bundle Impingement Shielding
To remedy this, add center studs to the partition plates so that enough force
is applied at the gasket ribs. Place the center studs evenly along the length of
the partitions. This involves drilling and tapping bolt holes or welding studs
to the plates. Drill the head to accommodate the extra bolting.
Tubesheet deflection is another common mode of partition failure, and it is
eliminated by proper bolting practices and the avoidance of thermal and
pressure stressing.
Due to pressure and thermal loading, especially when the loads are cyclical,
partition plate welds are prone to fatigue cracking. Feedwater heaters with
large thermal stresses and fluid temperature ranges are prime candidates.
When replacing or repairing partition plates, a full penetration weld is
superior to a fillet weld because a fillet weld repair is more susceptible to
corrosion attack and stress concentration.
Insufficient heat transfer with a TEMA F (longitudinal baffle) exchanger can
be the result of fluid bypass across the baffle. The fluid does not traverse both
shellside passes and instead bypasses between the shell and the baffle. The
integrity of the seal between the baffle and shell should be checked and
repaired.
3
FOULING MECHANISMS
Although the exact mechanisms and rates are not well understood, fouling
and corrosion can be classified into several groups. Numerous factors dictate
fouling rates and types. In all cases, even a thin film can significantly lower
the heat exchanger’s capacity. It must be kept in mind that the shear stress at
the tube wall controls fouling, not just the bulk velocity. The design of the
cooling system influences fouling susceptibility as given below.
Table 1
Cooling System Design and Fouling Susceptibility
Figure 5a
Stress Corrosion Cracks in a Low-Pressure Feedwater Heater
at the U-Bends
Figure 5b
Pitting Corrosion Damage of Carbon Steel Tubing Due to a Salt Water Leak
The growth and presence of bacteria, algae, mussels, and other biological
3.4 Biofouling
organisms in the fluid and exchanger components is a serious occurrence in
open cooling systems. The water condition and properties plus available
nutrients dictate the rate of fouling.
4
FOULING AND EROSION CONTROL
5
GENERAL INSPECTION
9
4 6 15 14
11
7
1
5
10
3 8 12
2 13
1. Inlet erosion and uniform wastage 7. Midspan fatigue cracks 13. Deposit-type pitting &
2. Cavitation and erosion pitting 8. Dealloying electromechanical
3. Debris or “clamshell” pits 9. Overrolling or freeze bulges corrosion filling
4. Support wear 10. Stress corrosion cracking 14. Overrolling at tubesheet
5. Fatigue cracks 11. Steam erosion 15. Manufacturing defects
6. Tube-to-tube wear 12. Corrosion at supports
Figure 6
Typical Heat Exchanger Tube Degradation
(Source: CenterLines, Vol. 7, No. 2, EPRI NDE Center, Charlotte, NC, 1996.)
Attention is given to the seals in floating head units of the TEMA P and W types.
These seals must be disassembled and maintained per the manufacturer’s
instructions. Excessive tightening causes extra load on the joint and restricts the
tubesheet movement, thus defeating the joint’s purpose. Because of this, a small
amount of packing fluid leakage is acceptable. The metal sealing surfaces ought
to be protected carefully when they are handled because small dents, scratches,
and scrapes will damage the sealing ability. A small defect when applied to a
high-pressure fluid containment is serious because fluid passing through the
defect at high velocity quickly damages the adjacent metal surfaces.
Fatigue cracks in the tubesheet ligaments can signify excessive tube vibration
that is transmitted to the tubesheet via the tube-to-tubesheet joint. It is critical
to identify the basis for tube-to-tubesheet joint failure (erosion, corrosion,
vibration, and others). A joint can be repaired only a few times before the
material is work-hardened or over-stressed.
Tie rods, baffles, and spacers are examined for damage, particularly for
corrosion from the fluid or from chemical cleaners, if used. Failure of these
components can shift and/or rotate the tube bundle and severely reduce the
exchanger capacity. The gaps between tie rods, baffles, and spacers are good
candidates for fouling and corrosion. Welding these components reduces the
degradation potential.
6
NONDESTRUCTIVE TESTING
Ultrasonic testing (UT) utilizes very high frequency sound waves to find
6.2 Ultrasonic
Testing material boundaries and faults. Although the method is rapid, compared to
radiography, an experienced operator provides the best results. There is a
potential for incorrect interpretation of data in certain areas, for example, at
backing rings.
For tubing, ultrasonic inspection is considered a supplement to eddy current
testing. The principle drawback to ultrasonic inspection is the fact that the probe
takes about ten times longer to travel each tube. Also, a thorough tube cleaning
is necessary. Nevertheless, UT is a useful technique when eddy current data are
questionable, for example, wear at baffle holes, which is not easily detected by
eddy current. Thus, the recommendation is to use eddy current testing on the
tubing first and then use UT to reexamine problem areas. Recent developments
have made ultrasonic probes available to inspect U-bends.
A liquid penetrant dye exposes cracks and seams in the material being
6.4 Liquid Penetrant
Testing examined and its porosity. The cost for such an examination is low, and the
dye is easy to apply but is not effective on rough surfaces. Typical uses
involve nozzle attachment welds, welded or brazed tube-to-tubesheet joints,
and tubesheet ligaments.
Magnetic particle testing can discover shallow defects. Its common use is on
6.5 Magnetic Particle
Testing nozzle attachments where radiography is not possible.
be utilized. Also, note that hydro testing is not effective in exposing near-
leaking tubes with only indications of pitting due to the high strength shoul-
dering effect around the pitted surfaces.
Alternatively, place gas pressure on the shellside; cork all the tubes on both
ends; and observe which corks pop out. As a precaution, a transparent,
protective shield must be fixed between the observer and the tubesheet to
avoid injury resulting from escaping corks or other plugs. For smaller leak-
ages, one tube end is blocked with a rubber stopper and the other end is
fitted with a single-hole stopper having a small section of flexible tubing
through it. The free end of the tubing is inserted into a vessel of water. If a
leak exists, the escaping gas is forced into the tubing and bubbles are visible
in the water vessel. The procedure is repeated for every tube. Obviously, this
is a time-consuming exercise and can take many minutes per tube or days to
complete the entire bundle; thus, it is advised only when other methods of
detection have failed to disclose the leaks.
7
FOULING IN-LINE ANALYSIS
Guidelines are available to assist the heat exchanger user in determining the
extent of fouling or degradation. By using these industry guidelines, cleaning
and maintenance tasks can be better assigned. The number of units to be
tested can be reduced by observing heat exchangers that have similar duties
and flow conditions.
8
TUBE BUNDLE CLEANING
U-tubes and finned tubing are difficult to clean, but plain, straight tubes are
cleanable by mechanical, hydraulic (hydroblasting), and chemical means and
can be inspected throughout their entire length. On the shellside, a large, 90-
degree tube pitch facilitates cleaning. A 1/4" (6.5 mm) wide space between
tubes must be present for a hydraulic cleaning of a tube bundle. Otherwise,
the pressurized water cannot penetrate the bundle’s interior. For this reason,
a triangular tube pitch is harder to clean than a square one. A hydroblasting
pressure of 8,000–10,000 psi (550-690 Bars) is typical but can range up to
18,000 psi (1240 Bars). For fixed tubesheets, chemical cleaning is usually the
only alternative unless generous clean-out ports are provided. In the instance
of floating head units, the bundle can be chemically cleaned while in the
shell. Or the bundle can be removed and washed mechanically, chemically, or
hydraulically as long as the tube pitch provides a minimum of 1/4" (6.5 mm)
empty spacing.
However, do consider the thermal stresses and potential detrimental effects
on exchanger components from a hot steam hydraulic cleaning. The possible
effects include tubesheet bending and tube bowing. Similar guidance holds
for U-tubes with the added complication of access to tube surface within the
U-bends. Due to the large bundle-to-shell clearance and the resulting low
velocity in this region, TEMA T shell sides are susceptible to fouling and may
need frequent attention. This drawback is somewhat tempered by the fact
that the bundle is easily removed.
Automatic cleaning machines, down to 1/2" (12.0 mm) tube OD, are easily
8.2 Tube Brushing
obtained, but smaller tubes can call for manual brushing. It is recommended
to remove each head at both ends because it is difficult to fully flush out
debris with one end closed.
For brushing soft (copper) tubes, exercise caution when using hard, coated
brushes or cleaning balls. Additionally, observe caution while cleaning brass
tubes with metal tube scrapers. Scratches in the tube wall could result from
the metal scrapers, and these scratches can tend to preferentially corrode due
to an upset in the tubing surface oxide protective layer, leading to a pitting
corrosion concern. In general, the choice of brush is dependent on the fouling
encountered and the tube material. When in doubt, first try the procedure on
a sample tube, outside the exchanger, and verify that base metal is not being
damaged or removed by the proposed procedure. Tube brushing is limited to
straight tubing. U-bends are not cleaned by mechanical brushing.
Also, when using individually shot tube brush cleaners, an apparent prob-
lem exists in ensuring foreign material exclusion. Accountability of the
brushes or balls must be maintained to ensure that no brush cleaners are left
in tubes that could result in adverse system operational problems due to
foreign objects in the system. This particular problem is more sensitive when
accounting for large numbers of brush cleaners in exchangers that contain
thousands of tubes. One solution to this problem is to use a mechanically
rotated brush attached to a cable that is fed down each tube. Hand feeding
the cable and brush through the tubes can be time consuming. But low cost
equipment is available that automatically feeds a cable-attached rotating
brush down through a tube and back at an efficient speed.
9
STORAGE
10
GENERAL HEAT EXCHANGER REPAIR
The ASME “U” stamp covers only new construction; the National Board
Inspection Code (NBIC) is recognized by most jurisdictions as the document
to follow for repairs and alterations of pressure vessels, including heat
exchangers. Any repairs or alterations are under the jurisdiction of the
locality that is ultimately responsible. The National Board is not responsible
for work. It acts on behalf of ASME and promotes and sets uniformity of
rules, trains and certifies inspectors, and registers pressure vessels.
The “R” (for Section VIII vessels) or “NR” (Section III heat exchangers) stamp
is usually necessary for alterations and for repairs when welding is per-
formed but always consult with the Authorized Inspector (AI). If welding is
not done in the course of an exchanger repair, the repair facility does not
need to hold approved ASME Code stamps. Thus, it is wise to discuss the
work plan with the AI prior to initiating changes. The construction repair
must comply with the edition of the ASME Code at the time of the original
construction, or any later edition up to the current one if the design features
are applicable to later editions. The inspectors recognize that it is not always
practical to adhere 100% to the ASME Code; thus, alternate methods can be
substituted. (A postweld heat treatment is an example of a technique that
might not be feasible for an existing heat exchanger under repair.) All weld-
ing must comply with ASME Section IX and plant welding procedures (a
common procedure regarding the use of backing strips, which are undesir-
able from a corrosion viewpoint).
Most joint problems occur on the inside face (shellside) of the tubesheet
10.1 Tube-To-
Tubesheet where the bending stresses are greatest. Tube joints that are only welded can
Joint Repair suffer from corrosion in the gaps between the tube walls and tubesheet holes.
At the same time, these bonds can crack from the normal expansion and
where,
ID = Measured tube inner diameter
OD = Measured tube outer diameter
Clearance = (Measured tubesheet hole diameter - OD)
Commonly, wall reduction varies from 3–12%. Overrolling can distort the
tubesheet and ligaments, produce high residual stresses (increasing the chance
of stress corrosion cracking), and work-harden materials in the tube ends,
while underrolling fails to develop sufficient joint strength and joint seal.
From the above equation, the original percent wall reduction is computed.
The rerolling should cause a percent wall reduction equal to 1.1–1.2 times the
original value. (As an example, if the original wall reduction was 10%, the
rerolling should be set at 11–12%.)
The roller is set for the correct ID from adjustments through rolling the first few
joints. Once tooling is set, it is a very routine procedure. Factors such as im-
proper rolling torque and sequence can damage a tubesheet. Thus, it follows
that only qualified, experienced personnel should perform tube rolling.
nate the weld with porosity, primarily when the tubes are already rolled.
Only a complete cleaning of the area and practicing the procedure on test
samples afford a chance for quality weld seals. The finished welds cannot
interfere with any gasket or pass partition. In most cases, it is best to weld
first and then roll to avoid trapping weld gases.
Along the same lines, braze repairs are formidable because it is difficult to
evenly heat the area of repair. The success rate is low with the best chances
on brass and copper construction.
Unless specified on the heat exchanger data sheet, obtained from the manu-
10.3 Tube Plugging
facturer, calculated, or stated in the TEMA guideline, no tube plugging
margin can be assumed. The TEMA value allows plugging of 1% of the tubes
or two tubes, whichever is greater. It is valid only for large tube bundles.
When a tube plugging limit has been justified, a suitable plugging method
must be selected.
It is useful to provide for a tube vent by ensuring that the tube has a hole to
relieve pressure after plugging in order to prevent pressure build-up in the
tube. An unexpected pressure build-up can force the plug out unless the plug
is welded. Excess plug material can be cut and removed, if desired.
A record of tube plugging and replacement is an asset to long-term mainte-
nance and repair. A list of relevant data includes:
• Date of repair
• Tube location
• Longitudinal position of damage (if known)
• Circumferential position of damage (if known)
• Root cause of failure (reason for plugging)
• Physical condition of tube and its neighbors
• Any NDE test results
Collar
Tapered
Pin
Figure 7
Common Manual Tube Repair Plugs
(Source: ABCs of Condenser Technology, Electric Power Research Institute,
Palo Alto, CA: August 1994. Report TR-104512.)
10.4.2 Sleeves
Ferrules are sleeves of brass, carbon steel, stainless steel (common), and other
metals that are slipped inside the tube and rolled to seal. The ferrule diam-
eter must be sized correctly. When in place, the lip of the sleeve covers the
damaged tube-to-tubesheet inlet area. Note that the tube diameter is slightly
remnants in the joint and grooves should be carefully scratched out with a
small tool. The joint and new tube must be clean before insertion.
One sample method for retubing fixed tubesheet heat exchangers involves
pulling and replacing tubes in a four-phase arrangement. Each phase in-
cludes a removal of one-fourth of all the exchanger’s tubes, cleaning the tube
holes, and subsequent tube replacement. The tubes are removed and re-
placed in a pattern of every other tube in every other row that allows a
complete surrounding of the removed tubes with old tubes, which limits the
chance of tube lane crossing when inserting the new tubes.
One factor that adversely limits normal tube replacement is a severely
twisted tube bundle. Severe twisting could make for higher than desired tube
pushing or pulling forces from drag in the baffle holes. The bundle can
distort from its operating conditions or from insufficient internal attachment.
The straightness of the bundle can be verified by visual sighting through the
tubes with a strong light on the opposite side. If the light cannot be sighted
through the tubes, it indicates some bundle alignment problems where
retubing might be a concern.
With fixed tubesheet designs where the bundle has a definite twist, an
alternate retubing process is employed that uses multiple shell access holes
cut along the axis of the bundle between the tie rods. The bundle is com-
pletely detubed, starting in the area in front of the access shell holes and
working inward. With physical access to the shell, straightening of the tube
bundle or other alignment repairs can be accomplished prior to replacing the
tubes. Shell access affords an excellent opportunity to fully inspect the
bundle cage (tie rods, baffles, spacers, and so on) and to thoroughly clean the
shell of debris from tube cutting and pulling. Tube insertion alignment is
maintained by physical reach through the shell holes. New tubes are filled in,
starting at the opposite side of the shell window holes.
Each new tube should measure 1/8" (3 mm) longer than the original; the
excess, after insertion, must be trimmed off with a conventional tube trim-
mer. Clean away the trimmings and roll the tube ends. It is safer to underroll
and reroll than to overroll, which might damage the tubesheet. The rolling
tool must be kept lubricated, and the space between the tube and tubesheet
kept clean and free of the lubricant and any other contaminant.
In any case, the root cause for all tube failures needs to be ascertained to
prevent future degradation. Simultaneously, tubes near the failed ones
deserve close inspection because damage often occurs in a group or pattern.
When removing the heads, mark each of them in such a way that it can be
10.7 Heads, Channels,
And Gasket Joints replaced in the exact position as before. A marking pencil is a good way to do
this. Also, use proper lifting components (lugs) and techniques to avoid
damage to exchanger components or surrounding equipment. The manufac-
turer can be contacted for lifting instructions if there is any doubt.
Follow the vendor instructions during unbolting a head (or any other gasket
joint). Failure to do so can permanently distort the joint when gasket forces
are released and concentrated. A common mistake is to completely loosen
and remove each bolt in one pass.
To reinstall the head, take care not to move the gasket when aligning the
heads. (Ensure that the gasket is not blocking tubes.) Follow the
manufacturer’s procedures for torque, torque pattern, and number of torque
passes when seating the gasket joint. Samples of torque patterns for different
numbers of bolts and joint patterns are available in Figure 8.
1
1 1
7 12 5
5
8 9
4 3 4 3 4 3
10 7
6 8
2 6 11
2 2
20 1 23
11 1 16 9
15 17 1 13 8
7 5 11 5 5
7 9 12 13
13 9
15 20 22
17
4 3 4 3 4 3
10 14 19 16 18 21
6 8 10 8
6 12 14 11
16 2 12 14 2 18 6 7
10 15
24 2 19
4 2
6 8
9 10
7
5
1 3
8 4 1 5 9
11 12
7 3 2 6 10
Figure 8
Sample Bolting Patterns for a Gasket Joint
(Source: Bolted Joint Maintenance and Applications Guide. EPRI,
Palo Alto, CA: December 1995. Report TR-104213.)
The head or flange ought to seat the gasket, not crush it. A large amount of
gasket protruding from the edge of a flange joint indicates over-tightening
and gasket extrusion. Lubricant must be applied to the bolts prior to tighten-
ing. Several passes at the specified torque and in a staggered pattern consti-
tutes the norm. For complete certainty of bolt preloading, the bolt elongation
is determined. (Contaminants and defects in the bolts and/or nuts distort
torque readings.) A bolting procedure might call for a recheck of torque at a
later date to compensate for gasket relaxation or expansion. Distorted bolts,
covers, and flanges are a sign of improper fastening. Although unexpected,
high pressures in the vessel can produce the same effect.
Waterboxes, heads, channels, and nozzles can also be epoxy coated like
tubesheets. The coating is applied in several passes to build a layer at least
1/16" (1.6 mm) thick; thicker build-ups can be employed if needed; however,
caution must be exercised when coatings are applied because the total anodic
surface area is reduced. The uncoated areas can be subject to accelerated
anodic attack as a result.
The gasket is an integral part of the exchanger, and its construction is based
10.8 Gasket
Replacement on a design that considers pressure, temperature, and thickness of mating
surfaces. Therefore, consult the manufacturer to obtain an exact replacement
that matches the material, thickness, and strength. If practical, replace the
gasket when unbolting a joint; the exception is for plate heat exchangers
whose gaskets can be used repeatedly.
Clean the mating gasket surfaces before replacement. A scraper or wire brush
with a cleaning agent aids in removing gasket remnants. Always take the time
to examine the old gasket for deterioration. If there is extensive uneven crushing
of the gasket, an alternative gasket/flange design should be considered. Check
the new gasket for defects. If the gasket is to be reused, clean it with water using
a soft brush, sponge, or rag. In addition, the flatness of the heads and tubesheets
ought to be verified. If the flatness is not within 1/32" (0.8 mm), sealing prob-
lems might be encountered, depending on the specific gasket. If the surfaces are
significantly distorted, a component repair or replacement is advised.
Similar procedures apply when dealing with packing seals. TEMA P and W
designs contain packing that must be properly handled and reinstalled, per
the vendor’s instructions.
11
PLATE HEAT EXCHANGERS
Roller Moveable
Inspection Assembly Cover Gasket Carrying Bar
Cover
Plate
Pack
Support
Column
Stud
Bolt
Support
Foot
Fixed
Cover
Guide
Bar
Figure 9
Plate Heat Exchanger
(Source: Alfa Laval Thermal, Inc., Richmond, VA)
12
COMPACT HEAT EXCHANGERS
Compact heat exchangers are small units that are characterized by extended
or augmented surface areas. Cleaning is not always feasible because of the
construction of the extended surface, and it might be cost effective simply to
replace the cooler when fouled. Repairs are difficult for the same reason, and
the equipment manufacturer should be consulted for guidelines.
13
AIR COOLERS
Power water washing is a simple technique to clean the fins of an air cooler.
Other than fouling, air flow obstructions are the major cause of reduced capac-
ity. This type of exchanger is susceptible to absorbing sources of heat due to its
large surface area. Guidelines for shell-and-tube exchangers can be extended to
the tubeside and waterbox exchangers, but maintenance and operational issues
regarding the airside must be taken up with the manufacturer.