Heat Exchangers Maintenance &

Repairs

By : Ashraf Anjum /Muhammad Ali

 Contents

• What is a Heat Exchanger

• Types of Heat Exchangers
• Exchanger Components
• Heat Exchanger Construction
• Maintenance of Heat Exchanger
• Diaphragm Type Heat Exchanger
• Special Consideration in Diaphragm Type
Heat Exchanger Maintenance
• Old Bundle Re-Tubing
 What is a Heat Exchanger

It is an equipment used to exchange heat between two fluids i.e.

heat flows from the hotter to colder fluid. The specific name is
given to any heat exchanger according to its service.

• Heater Exchanger used to heat process fluid

• Cooler Exchanger used to cool process fluid

• Condenser Exchanger used to liquefy vapors

• Vaporizer Exchanger used to vaporize liquid

• Pre-heater Exchanger used to heat process fluid to some

extent, utilizing waste heat, prior to its actual
heating process.
 Heat Exchanger

• Re Boiler Exchanger used to 'reboil' the fluid during the

process at a particular stage.

• Chiller Exchanger used to cool down a process fluid

by evaporating a refrigerant. Usually used
when required cooling is unattainable by
cooling water.
 Heat Exchanger Types
Heat exchangers can be classified by:
• Construction
• Flow Arrangement

By Construction
• Shell & tube heat exchanger
• Plate heat Exchanger
• Tube Fin Heat Exchanger

By Flow Arrangement
• Parallel Flow Heat Exchanger
• Counter Flow Heat Exchanger
• Cross Flow Heat Exchanger
 Heat Exchanger Types

Shell & Tube Heat Exchanger

Plate Heat Exchanger

Heat Exchanger Types

Tube Fin Heat Exchanger

 Heat Exchanger Types
Parallel Flow

Cross Flow
e.g. CT-2, Fin Fan
Cooler
Counter Flow
 Heat Exchanger Components

1 Tubes 7 Pass Partition

2 Stationary Head 8 Support Saddle
3 Stationary Head Flange 9 Transverse Baffles
4 Expansion Joint 10 Tie Rods
5 Stationary Head Nozzle 11 Shell
6 Tube Sheet 12 Shell Nozzle
 Heat Exchanger Construction

Tubes
OD Range : 1/4" - 2-1/2"
Commonly used OD : 1/2" , 3/4" , 1"
Standard Tube Lengths : 8, 10, 12, 16 & 20 FT (Max 40ft)
Commonly Used Lengths : 16 & 20 FT
Tube Wall thickness range : 18 - 10 BWG

Tube Sheets
Tube sheet is a round or square plate in which
tubes are fixed.

Shell
Outer Hollow Piece
Tubing Characteristics
 Heat Exchanger Construction

Baffles
Baffles are used to
1. Support the weight of tubes
2. Increase the turbulence of fluid

Tie Rods
Tie rods support the baffles

Boonet/Channel/Head
Used to feed or collect the tube side fluid
 Maintenance of Heat Exchangers
Safety Precautions
 Hold a job specific talk at the start of each shift.
 Before starting the job be sure that you have work permit both
for job and cranne entry in the plant.
 All rigging activiies must be carried out in presence of ECPL
supervisor.
 If a crane is used make sure you watch every movement of the
crane.
 Cordon off the area before removal of covers.
 When the pulling Exchanger bundles whether at ground level or
in the air always make sure the the bundle is pulled out straight
and level.
 If pipe support have to be used do not put too much strain on
them.
 Wear gloves.
 Maintenance of Heat Exchangers

Safety Precautions
 Ensure that pneumatic grinders are properly guarded and proper
keys are available for replacing and tightening discs.
 While using HPWJ machine make sure to cordon off the area
and use all necessary PPE's mentioned in section 2.1 of MP-
WP-04
 Fill check list for HPWJ machine as per MPR-WP-04 /1/00 prior
to its operation.
 PPE's
 All manadory PPE's(goggles,shoes,ear plugs,working gloves).
 Craft related PPE's (Welding gloves,cutting goggles, face
shield,dust mask full face mask).
 Face shield, rubber gloves, gum boots overall(if HPWJ machine
is used.
 Maintenance of Heat Exchangers

IMPORTANT POINTS
– Check pressure rating of flanges before installing blinds.
Use correct type of blind.
– Find out the pressure at which the pressure is to be tested
as per MPR-WP-11/7/00.
– While filling water make sure that the air can be bled out.
– Always bleed air from upper most point.
– While installing test ring make sure that it is of the right type
and meant for that particular exchanger.
– While plugging tubes make sure you have identified the
same tube from both ends.
 Maintenance of Heat Exchangers

 Do not stand under the load.

 Always have a good footing when working off ground.
 Pull bundles slowly so that the back end will not jerk out suddenly.
 When using skids and rollers keep hands clear of rollers."think today, be
here tomorrow".
 Maintenance of Heat Exchangers
 Getting relevant permits from operation supervisor.
 Blinding inlet/outlet lines of shell and tube side of heat exchanger if
required.
 Rigging arrangement for removal of tube bundles/exchanger.
 Pulling out of tube bundles from shell if tube sheetis not fixed type.
 Shifting of bundles in exchanger cleaning area near Motor Pool
area if required.
 Cleaning of tube bundle.
 Cleaning to be inspected by process.
 Hydrotest of exchangers.
 Plug tubes if leaking.
 Shift exchangers to site.
 Get Exchanger boxup certificate as per MPR-WP-06/02/00.
 Reinstall in position.
 Remove blinds.
 Houskeeping of the area
Internal Exchanger View
Tube Bundle
 PRESSURE TESTING OF HEAT
EXCHANGERS INSTALLING TEST RINGS
AND PLUGGING OF TUBES
Installing blinds on inlet and outlet lines.
– Check size and pressure rating of flange.
– Find out the test pressure of exchangers.
– Select blind of correct thickness and size.
– Clean flange surfaces.
– Install blind.

Install test ring

– Remove floating end cover.
– Identify the testing ring for the particular excahnger.
– Install test ring as per its particular procedure.
 PRESSURE TESTING OF HEAT
EXCHANGERS INSTALLING TEST RINGS
AND PLUGGING OF TUBES
Hook up test pump
– Get test pump from the tool room.
– Connect it to the lowest bleeder in the exchanger
using connecter and 3/8" tubing.

Fill water
– Fill water from lowest point.
– Bleed air from the highest point.

Pressure test
– After the water is full, pressureize exchangeer with
the pump.
 PRESSURE TESTING OF HEAT
EXCHANGERS INSTALLING TEST RINGS
AND PLUGGING OF TUBES
– Check tubes for leakage and plugging. Before checking
tubes for leakage blow air into the tubes so that any water in
the tube is blown out and the tube is completely dry.
– If a tube is leaking water will start dripping out of it. Mark the
tube and check its orientation. Identify te tube on the other
side and prepare the ends for plugging. Check the tube
ends. If they are eroded to the extent that the tube sheet is
showing. It might not be advisable to plug the tube.
– Plugging
Use tapered plug available in the warehouse. Choose teh correct
size. Install it inside the tube and hammer it with a 2lbs hammer.
 Heat Exchanger Construction

Gaskets

Following FOUR material of gaskets are commonly

used.

1. Non asbestos gaskets

2. Soft iron/Aluminium gaskets

3. Metal Jacketed Gaskets

4. Metal Diaphragm
 Diaphragm Type Heat Exchanger

Diaphragm Type Heat Exchanger is a High pressure exchanger

in which headcover leakage is prevented by welding a metal
plate to the channel head.

Maintenance of diaphragm type heat exchjnager is critical

becuase if leakage occurs past the diaphragm after exchager
startup, it cannot be stopped without a shutdown.
 Diaphragm Heat Exchanger Maint.
Following is a step by step sequence of activities for Maintenance of a
diaphragm type heat exchnager

Preplanning Activities
• Check availability of spare diaphragm
• Check condition of spare diaphragm
• Check partition plate gasket and other spares (gouging electrode,
bare wire for plugging of tubes & welding of diaghragm, argan
cylinder, oxy-acetylene cylinders etc.)
• Take welding procedure for welding of diaphragm from inspection.
• Install proper scaffolding as per standard.
• Check availability of headcover spanners and other tools.
• Prepare jig for lapping and installing a diaphragm.
• Arrange blinds as per list.
• If weight of headcover is more than 4 Ton, fill Rigging card
 Diaphragm Heat Exchanger Maint.

Hazzards associated with the job

• Whipping of air hose due to improper connection
• Whipping of air hose due to rupture
• Impropoer tools & equipment
• Backfiring of heating set.
• Improper rigging
• Improper scaffolding
• Objects falling
• Explosion/fire due to improper exchanger purging.
• Damage to diaphragm due to improper gouging.
 Diaphragm Heat Exchanger Maint.

Start the Job

– Install blinds in shell side

connections.
– Match mark headcover with
channel head
– Mark stud numbers on nuts
and tube sheet.
– Open head cover bolts and
store in proper location.
Diaphragm Heat Exchanger Maint.

– Remove headcover by rigging

– Cordon off the area with fire cloth

and check explosivity.

– Insert Kaowool in stud holes, so

that the threads are not damaged

during gouging.
 Diaphragm Heat Exchanger Maint.

– Gouge out the diaphragm

with the help of a qualified
person.
– Open & remove partition
plate.
– Carry out pressure testing
OR leak test as per
inspection recommendation.
– Dye check of tube sheet. If
defects are found, repair
them as per procedure from
inspection section
 Diaphragm Heat Exchanger Maint.
– Check straightness of cover plate
gasket area through strainght edge.
In case correction is required, take
the cover to shops for machining.
– Check straightness of channel box
gasket area through strainght edge.
In case correction is required,
perform grinding or lapping
depending on the amount of defect.
– Check tapping of male/female bolt
threads. Carryout tapping in case
there is any defect.
– Check size & material of gasket.
 Diaphragm Heat Exchanger Maint.
– Fill boxup for partition plate
– Place gasket in its area and engage it either with masking tape or hard grease and then
Install partition plate.
– During tightening of the bolts of partition plate, follow the proper sequence of tightening
from center towards the end on both sides. Use washers under the bolts for proper
tightening.
– After tightening, tag weld the bolts so that the bolts donot become loose after expansion
takes place when the exchanger temperature rises when put in service.
– Check diaphragm seat for any damages during diaphragm removal. If defects are found,
repair them and carry out lapping.
– If diaphragm is being reused, carry out dye check of diaphragm and carry out repairs if
any.
– Place the diaphragm in its seat. Then press the diaphragm either by a jig or with the help
of spacers and headcover.
– Clean the welding joint.
– Preheat the diaphragm to tubesheet joint at the specified temperature.
– It is better to carry out Argon welding on all the diaphragm welding passes.
– If Electric welding electrodes are being used, then these should be heated in the oven for
atleast 2 hours prior to their use.
 Diaphragm Heat Exchanger Maint.

– Carry out rootpass of the diaphragm

to tube sheet joint with an ECPL
welder.
– Donot carry out the weldiong in
Down hand position.
– Allow the weld joint to cool down for
Dye check
– Carry out Dye check.by ECPL
inspector.
– Apply the remaining welding passes
maintaining the preheat temperature.
– Ensure that the welding start and
stop points are stagerred.
 Diaphragm Heat Exchanger Maint.
– Carry out final Dye check.
– Remove insulation from stud holes
and clean the holes with air.
– Install studs.
– The install headcover and tight first
four bolts as per sequence and trhen
check space between the cover and
the head. Space should be equal all
around.
– Tight remaining bolts as per
sequence
– Remove shell connection blinds.
– Remove scaffolding and carry out
housekeeping.
– Return the permit.
 Past Problems
Leakge Past Diaphragm
Problem occurred due to:
• Improper lapping of diaphragm seating surface
• Improper welding
• Welding start & stop positions not staggered
• DIaphragm not tightened properly

Leakage through Partition Plate Gasket

Problen can occur due to:
1. Improper tightening
2. Improper material of gasket with respect to temperature
and pressure.
3. Improper flatness of cover and tubesheet gasket area.
 Past Problems

Headcover stud Problem

Problem occurred due to
• Proper insulation not inserted in stud holes
• Studs not installed as per marking
• Studs not stored properly
• Cleaning of stud & stud holes not done.
 Old Bundle Retubing

Preplanning
– Check for approved bundle drawings.
– Check for adequate quantity of spare tubes, tube
spacers, tie rods, washers, C- Channel.
– Check for tools such as tube rollers, welding rods, tube
facer, pencil grinder, drift punch
– Verfiy drawing with old bundle.
– Number baffle plates with letter punch.
Old Bundle Retubing
Bundle Retubing
– Cut both tube sheets on circular saw.
– Place remaining bundle on C-Channel and dismantle.
– Place the tube sheet on table and heat the tubes to redhot.
– Then let the tubes cool and then remove the tubes from tube sheet with
drift punch.
– Shift the tube sheets to Machine shop for setaing surface checkup and
rectification.
– Fix the tube sheet in Vice and clean the tube sheet holes with pencil
grinder.
– Then place the tube sheets on C- Channel and assemble the cage.
– Clean 3" portion of tube ends for ease of insertion.
– Start inserting the tubes one by one.
– Have the baffle orientation and other dimensions checked by supervisor.
– Clean the tubes from inside with emery paper.
– Start the tube rolling process.
– Similarly start the tube rolling process from the other side.
Thanks