In todays modern world, it is primary need for Petrol, Diesel & various petrochemical products.

It is difficult to think of life without petrochemical products. These products reaches passing through refineries & petrochemical plants after various processes. It means, the process industries becomes the primary requirements. These process industries (e.g. Refineries, cracker plants, hydrocarbon product processing) use Heat exchanger .Heat exchanger is good transferring heat one liquid to other liquid at various temperatures. Heat exchanger is used to contain a multiple thing including air, water, chemicals, and fuel. They are used in paper and pulp, energy, food, chemical industries. Heat exchanger is designed with great care because rapture of a Heat exchanger means an explosion which may cause loss of life and property.

INTRODUCTION:-

Definition of heat exchanger:-

Thermal System of heat exchanger

The purpose of a heat exchanger is to transfer energy from one fluid to another. Many different types of heat exchangers exist to accommodate different fluid properties. One of the simplest designs is the concentric tube heat exchanger used for heat exchange between two liquids. A device used for transferring or exchanging heat energy between two fluids is known as Heat Exchanger. This heat exchange can be exchange heat either by direct or indirect method:-

In the direct methods heat transfer between two fluids takes place without mixing. Two fluids are separated by a metallic or non-metallic surface, through which heat transfer takes place generally perpendicular to flow direction.

Effectiveness of heat exchanger:-

(T Effectiveness =
Where, to = ti = Ti =

to ti
i

ti

) = Inlet temp. diff . of hot & cold fluid

Cold fluid temp. range

Cold fluid outlet temperature Cold fluid inlet temperature Hot fluid inlet temperature

Define Heat Duty Of Heat Exchanger:Heat duty of a heat exchanger is defined as the heat that is transferred from hot fluid to cold fluid per unit time.

Define Capacity Ratio of Heat Exchanger:Ti To Temp. range of hot fluid = t t Temp. range of Cold fluid o i R=

Where, to ti Ti To

= = = =

Cold fluid outlet temperature Cold fluid inlet temperature Hot fluid inlet temperature Hot fluid outlet temperature

TYPES OF HEAT EXCHANGERS

Heat exchangers can be classified by different methods

Function: Process function such as re - boiler, condenser, cooler, heat recovery, steam generators etc. Design of heat exchangers is done based on a internationally acclaimed codes like ASME Section VIII (American Mechanical Engineers, New York) and TEMA standards (Tubular Manufacturers Association INC. New York) number of Society of Exchanger

Following types of heat exchangers are commonly manufactured:1. 2. 3. 4. 5. 6. 7. 8. FIXED TUBE-SHEET HEAT EXCHANGERS FLOATING HEAD HEAT EXCHANGER U-TUBE HEAD HEAT EXCHANGER SPIRAL HEAT EXCHANGER PLATE TYPE HEAT EXCHANGER DIRECT CONTACT HEAT EXCHANGER DOUBLE PIPE HEAT EXCHANGER SHELL AND TUBE HEAT EXCHANGER:-

The wide range of heat exchangers falls in this class. It consists of number of parallel tubes enclosed in a relatively close fittings cylindrical shell. One fluid flows inside the tube and is called the tube side fluid and the other flows outside the tube in the shell called as shell side fluid.

Flow paths: Co-currents, counter current cross flow etc

The function of the steam generator is to transfer the heat from the reactor cooling system to the secondary side of the tubes, which contain feed water. As the

feed water passes the tube, it picks up heat and eventually gets converted to steam.

The Shell and Tube is the most common type of heat exchanger used in the process, petroleum, chemical industries, it contains a number of parallel utubes inside a shell. Shell Tube heat exchangers are used when a process requires large amounts of fluid to be heated or cooled. Due to their design, shell tube heat exchangers offer a large heat transfer area and provide high heat transfer efficiency.

DESIGN PARAMETERS OF HEAT EXCHANGER:-

TYPES OF HEAT EXCHANGER COLUMMS:-

From the above introduction, it is becomes transparent that Reactors are required for refineries & process industries. There are various types of pressure vessel defined based on type of construction & manufacturing methods. SINGLE WALL VESSEL:-

These are the vessel made of carbon-manganese steel or alloy steels having single wall. These vessels generally work as lower pressure & temperatures. As they at lower pressures, the thickness required to withstand the pressure is less & can be achieved with normal plate rolling mills. This type of vessel is preferred in industries as it is easier to manufacture & cheaper in cost.

MULTIWALL VESSEL:-

Fertilizer plants use the vessels like Ammonia converter Baskets. These vessels are working at very high pressure and temperature, which in turn raises the requirement of very high thickness. It is difficult to roll such a high thickness & weld as pressure joint. In such cases, the technology used for manufacturing is opting for Multiwall vessel.

These vessels are manufactured based on simple principle of shrinkage with of help of temperature variation. In this method, the shell are made with small thickness in form of rings in such a way that these rings can fit within another with close tolerances. The outer ring is heated which allows expansion of that ring to higher diameter. The lower diameter ring is inserted within red hot outer ring & allowed to cool to normal temperature. As the temperature goes down, the outer ring shrinks & fits with inner rings. Generally there are more than 3 to 4 Vessel wall i.e. rings. Finally the higher thickness is achieved with multiwall, & therefore these vessels are called as Multiwall vessel. It should be noted that now-a-days, such vessel are obsolete due to difficult manufacturing & lot of heat treatment involved with very high accuracy. These multiwall vessels are now replaced by use of special alloy steel having chromium & Vanadium. CLAD VESSELS & OVERLAYED VESSELS:-

These vessels are specially designed for corrosive services. The reactors which process corrosive fluids are handled in Stainless steel environment. Clad vessels are manufactured out of clad plates. Elaborating little more, clad plates are the plate having Alloy steel plate & Stainless plate rolled together at higher temperature which allows bonding. The thickness of alloy steel plate is much higher than SS plate because of the strength is given by outer Alloy steel & corrosion resistance is provided by SS inner layer. The manufacturing sequences are similar like single wall vessel with a difference of extra care during rolling of clad plate having SS buffed surface inside. Another option for such corrosive services is carrying out Stainless Steel overlay inside the Alloy steel shell after rolling to required diameter. This is more time consuming method as it requires generation of a complete layer of SS inside shell. On the other hand, this much cheaper than Clad Vessels. Overlayed vessels are now-a-days preferred much over clad vessel by Modern Process Licensors like IFP.

HIGH THICK HEAT EXCHANGER :-

As the chemical technology advances with fast pace, the refineries have now started using high production rate with smaller sizes of plants. In turns, the refineries requires high thickness Heat exchanger made of costly alloy steel contain Chromium Vanadium. These reactors work are very high pressures & temperatures with lot of automation inside. Hence, these high thick vessel (approx. 200mm & above) with special manufacturing technology & special skills.

DESIGN CRITERIA

Use a safety factor of 4 based on the known or calculated failure pressure of the Heat exchanger or ultimate strength of the material when designing for involves detrimental conditions, such as vibration, corrosion, shock, or thermal cycling. Never use a safety factor less than 4 when designing a vessel for mannedarea operation unless the design conforms to the ASME code or to the requirements listed in Section 4.9 of this document and is approved by the division leader. Have the Deputy Associate Director for Mechanical Engineering approve any manned-area Heat exchanger design that is based on a safety factor of less than 3. Design any vessel or system containing hazardous materials such that the contained fluid leak rate will not pose a hazard to personnel or the environment.

Material Selection
Select materials that remain ductile throughout the working temperature range of the vessel. If you cannot avoid using a brittle material for the body of a manned-area pressure vessel, your Department Head must sign the ESN. Select materials that are compatible with the liquid or gas to be contained in the vessel. Beware of hydrogen embrittlement. High-pressure hydrogen gas drastically degrades the ductility of highly stressed, high-strength pressure vessel materials. This problem can be solved using either one, or both, of the following methods: 1. Use lower-strength vessel materials such as type 304, 316, 321, 347, stainless steel; 2024 or 6061 aluminum alloy; oxygen-free copper; phosphor bronze; beryllium copper; or other materials recommended by a recognized expert in the field or through a peer review. 2. Include an inner liner (or bladder vessel) made of one of these hydrogen-resistant materials. When designing such a liner, be sure that it will withstand working and testing stresses. Consider positively

venting the liner/body interspace so that any hydrogen that penetrates the liner cannot subject the high-strength vessel body to high-pressure hydrogen. Provide means for periodic verification that the vent path is open to the atmosphere.

Design Considerations

Specify that all purchase-fabrication welding be done by certified ASME welders in accordance with the approved ASME Boiler and Pressure Vessel Code. 1 Avoid longitudinal welds in vessels less than 6 in. (0.15 m) in diameter. Seamless tubing or pipe, or bar stock is usually available in these smaller diameters. Avoid stress concentrations. This is most critical when vessel material elongation or fracture toughness is relatively low. Adjust the design and the allowable stresses to compensate for environmental conditions such as vibration, cycling, temperature fluctuation, shock, corrosion, and extreme thermal operating conditions. Specify inspection by appropriate nondestructive detection methods, such as radiographic, ultrasonic, dye penetrant, and magnetic particle inspection, when designing a high-strength, high-pressure vessel. Specify appropriate ultrasonic inspection of all manned-area pressure vessels with wall thickness over 2 in. (50 mm). Maximum permissible defects should be based on the capability of the vessel material to resist crack growth under the specified operating conditions. Contact the subject-matter expert for assistance with properly specifying ultrasonic inspection. Prepare a Fracture Control Plan for all gas-pressure vessels with wall thickness over 2 in. (50 mm) that are to be operated in a manned area. These vessels should be periodically monitored using appropriate nondestructive inspection techniques to assure that previously undetectable, undetected, and detected cracks are not approaching critical size. Contact the subject-matter expert for assistance. A plan should be prepared for vessels with thinner wall thick nesses wherever radioactive, toxic, explosive, or flammable materials are involved.

When specifying welding of Heat exchanger components, consider the following:

Checking a weld cross-section for toughness, because a weld might be brittle and welding might embrittle the material in the heat-affected zone. Including realistic joint efficiencies in calculations (see Ref. 1, Table UW-12), because a weld might not penetrate to the full thickness of the parent material. Including the reduced properties of the heat-affected zone when calculating the overall strength of the vessel, because welding normally anneals the material in this zone. Consulting with a welding or materials expert when planning to weld a vessel that will contain a high-pressure hydrogen gas, because welding reduces resistance of some materials to hydrogen embrittlement. Design all barricades for remote-operation pressure systems in accordance with the requirements in TEMA Code.

Comparison of two different Heat Exchanger

 Design of Heat exchanger as Per TEMA:-

 CONSTRUCTION :-

HEAT

EXCHANGER

Heat exchanger consist of various elements like Cylindrical Shell, Closing Head, various instrument & process nozzles, tube Maintenance openings, supporting structure & connecting Piping.

THE SYMBOLS USED IN FOLLOWING FORMULAS ARE BELOW

t = minimum required thickness of shell, inch. P = internal design pressure, psi . R = inside radius of the shell course under consideration, inch. S = maximum allowable stress value, psi. (Further info. See UG 23) E = joint efficiency. C.A=corrosion allowance DESIGN OF SHELL UNDER INTERNAL PRESSURE THICKNESS OF CYLINDRICAL SHELL DIMENSIONS OR (LONGITUDINAL JOINTS) (CODE REF. ASME sec VIII Div 1, UG 27)
t= PR + C. A. OR SE 0.6 P P= SEt R + 0.6t

IN

TERMS

OF

INSIDE

When thickness does not exceed one half of the inside radius, or P does not exceed 0.385 SE the following formula shall apply. THICKNESS OF CYLINDRICAL SHELL IN TERMS OF OUTSIDE DIMENSIONS OR (CIRCUMFERENTIAL JOINTS)

When thickness does not exceed one half of the inside radius, or P does not exceed 1.25 SE, the following formula shall be apply:
t= PR + C. A. 2SE + 0.4 P OR P= 2SEt R + 0.4t

OF HEAT EXCHANGER: CYLINDRICAL SHELL:-

MANUFACTURING

SEQUENCES

The cylindrical enclosure resisting pressure which called as Shell. This geometrically a cylinder undergoing circumfercial stress. These shell are manufactured by various ways like Plate Rolling Forged shell Plate rolling requires plate to be rolled from Steel plant. The plates undergo controlled temperature treatment & are tested to the requirements of Heat Exchanger. These plates are then rolled to form cylinders which are used to generate vessel wall. There are limitations on plate width while rolling & handling at Factory. This width restriction calls for Heat Exchanger to be made in segments. After rolling various shells of different widths, they are joined various welding methods like SMAW, SAW, GTAW, GMAW. This allows higher length of Heat exchanger & fulfills process requirements. Another method is used for very critical vessels working at very high pressure & temperatures. This type of shells provides smooth grain structure due to forming method of manufacturing. The manufacturing sequences are brief in diagrammatic.

1) PLATE

2) ROLLING

3) LONG SEAM WELD

4) CIR. SEAM WELD

5) SHELL

TYPES OF HEAD/ DISH ENDS:1) TORISPHERICAL HEAD:As shown, this type of head consists of profile generated by two different circles having Crown radius & Knuckle radius. There various aspects for selection of type head like volume inside head & space available above vessel at site. Generally these types of heads are used for low thick vessel.

TORISPHERICAL HEAD The required thickness of a Torispherical head for the case in which the knuckle radius is 6% of the inside crown radius and the inside crown radius equals the outside dia of the skirt, shall be determined by
T= 0.885 PL SEt + C.A. OR P = SE 0.1P 0.885 L + 0.1t

t = minimum required thickness of head after forming, inch. P = internal design pressure, psi. L = inside spherical or crown radius, inch. 2.ELLIPSOIDAL HEADS 3.HEMISPHERICAL HEADS 4.FLAT HEADS 5.CONICAL HEAD AND SECTIONS (WITHOUT TRANSITION KNUCKLE) NOZZLE:Nozzle is very important part of any vessel or reactors. Gases or liquid can be taken in or taken out from nozzle. Nozzles are working on various temperatures and various pressures. So it is very important to make nozzle to high accuracy and alignment of nozzle has to be done properly USE OF NOZZLE:as the Heat Exchanger are allowing fluid to come in get processed & go out, using various nozzle connection carries this work. The various nozzle use in such Heat Exchanger are listed below 1) SHELL SIDE INLET NOZZLE:-

This nozzle serves the purpose of taking fluid entering in to the Heat exchanger. This inlet nozzle provides at the top of the heat exchanger &it has withstood high fluid Pressure. This also consists of connection a flange. 2) SHELL SIDE OUTLET NOZZLE:This nozzle serves the purpose of taking fluid outlet in to the Heat exchanger. This outer nozzle provides at the bottom of the shell side in heat exchanger &it has withstood high fluid Pressure. This also consists of connection a flange. 3) DISH END SIDE INLET NOZZLE:This nozzle is providing on the top dish of Heat exchanger for the fluid inlet before Heat exchange reaction taken place in Heat exchanger. 4) DISH END SIDE OUTLET NOZZLE:This nozzle is providing on the bottom dish of Heat exchanger for the fluid outlet after Heat exchange reaction taken place in Heat exchanger. This nozzle is almost same size as inlet & requires elbow type construction for connecting pipes. TYPES OF NOZZLE CONSTRUCTION:1. 2. 3. 4. FLANGE -PIPE TYPE FLANGE-PIPE WITH PAD REINFORCEMENT LONG WELD NECK TYPE SELF REINFORCED NOZZLE

SELF REINFORCED NOZZLE:This is the most widely used construction of high thick vessel & reactors. In this type of construction, the nozzle opening is made from forged material machined to suit the shape required for reinforcement of nozzle cutout. This type of construction allows variation of pressure & temperature. The area shown as hatched is providing required reinforcement & the lip allows 100% radiography test can only be achieved using such type of nozzles. The calculation for nozzle reinforcement is carried out as per ug-37 of ASME section VIII.

SELF REINFORCED NOZZLE

Method of Manufacturing Baffles and Tube sheet

TYPES OF PITCH IN TUBE SHEET:1. Triangular Pitch 2. Rotated Triangular pitch 3. Square pitch 4. Rotated square pitch

A helical baffle for shell and tube type heat exchangers is fabricated by stamp forming a plate in the form of a partial circular section into a helical section between opposed, mating helically-shaped faces of two forming dies. The plate contains a series of apertures in the form of a pattern for receiving heat exchanger tubes. The dies contain sleeves and opposed reaming rods which form lips on the apertures during stamping of the plate. Lips can also be formed on the outer edge of the plate and the edge of a central passage during stamping. The lips prevent the helical plate from twisting or returning to a flat configuration. The leading and trailing edge of the helical plates are then joined such as by rivetting or welding into a continuous helical baffle with sets of heat exchanger tube apertures aligned along a common axis.

 FABRICATION PROCESS FOR MANUFACTURING HEAT EXCHANGER:Purchase material as per requirements Material received Material identification & inspection Plate cutting layout (PCL) Marking of Plate (With the help of 345 rules ) Cutting of Plate WEP (Weld Edge Preparation) Edge breaking Rolling & re-rolling Long seam set-up & inspection after and before welding Dend inspection Circular seam set-up & inspection after welding (Shell to shell or Dend to shell or Cone to shell set up) Inspection and testing Nozzle marking and punching Nozzle set-up inspection before and after welding Assembly Final dimension checking and surface finishing Heat treatment Hydro test and other helium test etc. Final inspection and painting

SHELL plate marking:-

When we want to marking of shell plate at that time the given method are used for marking and find out the shell plate length. Shell length and its diameter is given in drawing but their shell plate length is not given in drawing. To find out the shell plate length first of all find out their mean Dia with the help of given equation. Mean dia = outside diameter + inside diameter 2 Now this mean dia is calculate with (3.14) Length of the shell plate = mean dia of shell X 3.14 Length of shell = as per drawing Thickness of shell = as per drawing

3 4 5 rule (paithagoras rules):As per 345 rule marking is done with as per given sequence First of all select plate, which is used for cutting. After selection of plate clean plate dust, rust, oil, grease and other foreign particle, which is, removed either mechanically or chemically. After cleaning the plate whitener or chalk will be spray on plate than after light pointer punch will be used for marking.

5 3
900 B C

In 345 rule 3 Number related in mm, cm, inch are taken as per requirements 3 number taken in width or length side. Here draw line in width sideline AB (3). Number 4 is also taken on length or width in mm, cm or inch but always opposite side of number three means draw a line of BC (4). And then draw AC (5) numbers line in length to width direction and mark a point on 3 numbers line then draw a line center point and intersection of 3 & 5 that line is perfectly right angle (900) through the length. Cutting of plate :-

After marking the plate properly check the marking is ok or not if marking is ok then cut the plate as per facilities available in industries Oxy-acetylene cutting Plasma cutting machine CNC gas cutting machine In plasma and CNC gas cutting machine we speedily work done with good quality with minimum machining requirement as per comparatively oxy-acetylene cutting work.cutting allowances are comparatively lower in plasma and cnc machines. WELD EDGE PREPARATION (wep):-

After cutting the plate edge preparation is required to joining the two edge of plate in long seam of shell and in circumferential joint also edge preparation is required. Edge preparation is necessary to get good quality joint. the strength of edge prepared joint is comparatively higher than without edge prepared joint. Due to edge preparation we get good penetration. So edge preparation is necessary in 5 mm or higher thickness.

Edge breaking
Edge breaking is done before rolling procedure.because without edge breaking we not get required radius at the two rolling side edge of the shell. Because end portion of the plate cannot be rolled it is observed that when rolling, the end portion is left unrolled and ovality in shell shape is observed. To edge braking the sheet first of all we made template of the required radius. And edge breaking is done with the help of power press.

Rolling :-

In rolling procedure 3 roll shell rolling machine is used rolling procedure is done in two ways (hot rolling, cold rolling) depending on the following parameters Thickness of the plate Width of the plate Strength of the plate Dia of the roller After rolling process when we not get required radius at that time Re-rolling process is done to get perfect circularity. Long seam set-up and inspection after and before welding:-

Long seam set-up is done after rolling of plate for long seam welding. Long seam is welding is process of joining of two ends of rolled plate to form a complete shell.long seam set-up can be done in two ways. Single segmented A single plate is rolled completely to form a shell. In this case only one welding seam will be there. Multiple segmented When dia of the shell became to large at that time shell made in number of petals at that time two or more long seam are present in shell.

Welding M/C Shell

Boom Traverse

Boom

Column

Tank rotator Welding Manipulator

Long Seam Welding Set-up

Circular Seam Welding Shell Column SAW Head Tank rotator Welding Manipulator Boom

Set-up for circular seam welding between two shells

Procedure
Check weld edge preparation as per drg. Wire wheel 50-mm area around seam. Check the screw. Measure the outside circumference at both the ends and at center. Ensure proper root gap & root face. Ensure offset within tolerance. Put run in - run out plates & PTC as per job requirement. Recheck the circumference at both the ends & at center. Offer the set-up for inspection.

WELDING PROCEDURE:-

Welding is a process, which is used to join similar or dissimilar metals At this time number of welding processes available in industries. But generally arc-welding process is most popular in industries due to their advantages. The popular arc welding process in industries are given below. Shielded metal arc welding (smaw) Submerged arc welding (saw) Gas tungsten arc welding (gtaw) Gas metal arc welding (gmaw) Flux cored arc welding (fcaw) Shielded metal arc welding is manual welding process it is also known as manual metal arc welding (mmaw). When job is small or complicated at that time MMAW welding process is very useful. In this welding process flux coated electrodes are used. Submerged arc welding is an automatic welding process. When job is heavy or thickness of job is high at that time submerged arc welding process is used for get good quality of weld. In this welding process bare metal electrodes are used electrodes are generally copper coated. During welding flux is automatically feed from hopper. In heavy engineering division SAW process is widely used. In GTAW process non-consumable tungsten electrodes are used in this welding process after arc striking welding is carried out as a gas welding process. And welding is carried out in inert atmosphere of helium or argon to protect weld metal from environmental oxygen and nitrogen. And get good quality of joint. In GTAW process DCEN polarity is used because electrodes are non consumable. Inspection after welding In after welding inspection measure outer dia of the shell. Circularity of the shell if shell is not completely circular then remove ovality with the help of spider. Measure the length of the shell if length is higher than required length then trim the extra length of shell. Quality of the joint appearance of the weld is also check during after weld inspection. To eliminate or reduce distortion appropriate jigs and fixture used.

 inspection:-

Dished

end

manufacturing

and

Dished end either made in own industries if facilities available or get from other dend manufacturing industries. Dished end is manufacture in one parts or number of parts. When dia or size of the dend is smaller at that time dend is manufacturing in one parts. When dia or size of the dend is to large at that time dend is manufacture in the number of parts. Dished end is generally made through forming for form the dished end heavy hydraulic or power press became used. Inspection of dished end In inspection of the dished end first of all made one template of relative dend radius . All radiuses and their height are checked with the relative tolerance limits. If the radius of the dend is not match in tolerance limit of the dend at that time reforming is done and adjust radius and dimension of the dend. If height of the dished end is higher than required height the extra length is trim. After trimming check the entire dimension carefully their height, knuckle radius, crown radius, straight face of the dished end within tolerance limit given in the drawing. If dished end is made in other industries at that time all the inspection done as possible as manufacturers sight so if dimension is not match with the required dimension than repair is done at manufacturers sight.

Types of circ/seam set-ups. Shell to shell set-up Shell to dend set-up Shell to nozzle set-up

Circumferential seam set-up:-

Procedure of circ/seam set-up

Align shell on Tank Rotators Keep both the Shells on the shell tank Rotator. Match the end of shell to shell or shell to dend Keep Root Gap as per Requirement Check the root gap between shell and dend with the help of filler gauge Lock Four Orientation ( 0 , 90, 180, 270 ) (Keep offset as per the Circumference Difference.) Check Total Length After check root gap between shell and dend and final length tack the joint After set-up completion set-up issue for inspection

Inspection and testing:-

After completion job will be carried out in various inspection and testing (testing including destructive and non-destructive) In inspection including Visual inspection Dimensional inspection And in testing method destructive and non-destructive method includes Destructive method

The method in which test piece will be broken or bend is done that is known as destructive testing. Bend test Tensile test Impact test Etc. Non destructive testing The method of testing in which that piece will be not break or bend that is known as non-destructive testing. Radiography testing Ultrasonic testing Magnetic particle testing Liquid penetrant examination Helium leak test Etc. NOZZLES:-

Assembly of pipe or forging to flange is called nozzle. APPLICATION

Used for inlet or outlet connection. Used for man way.(always take 18 to 24 inch.) Hand hole. Used for fitting safety valve and devices. For vent connection. TYPES OF NOZZLE:RADIAL NOZZLE OFFSET NOZZLE TANGENTIAL NOZZLE ANGULAR NOZZLE RADIAL NOZZLE: A nozzle, which is perpendicular to base of the shell or dished end lies on the orientation line is called radial nozzle.

OFFSET NOZZLE: A nozzle, which is similar to radial nozzle but offset from orientation line, is called as offset nozzle.

TANGENTIAL NOZZLE: A nozzle, which is on any tangential line of the shell, is called tangential nozzle.

ANGULAR NOZZLE: A nozzle, which is at an angle from the reference line, is called as angular nozzle.

First mark the orientation of nozzle on shell or dished end. The elevation is marked and the radius of the nozzle is measured and marked on the shell. The marked line is punched The cut out on shell or dend is made with the help of any cutting machine. The cut out area is machined for welding and to get required surface roughness. The reinforcement pad is made ready for the set-up The reinforcement pad is mounted on nozzle cut out area The nozzle is checked for the ovality if found it is removed Then the nozzle is taken to the cut out and set-up begins The orientation of the nozzle is checked The elevation of the center is matched The orientation, elevation and level of the nozzle is rechecked Than tack weld is done Inspector checks these set-ups before full welding if the entire dimension is ready than full welding are done.

DEVELOPMENT FOR ANGULAR NOZZLE

 Tube to tube sheet welding:-

Tube to tube sheet welding Is performed to join the tube sheet in shell & tube type HE. Tube to tube sheet welding is used to ensure the required strength as well as the leak tightness of the joint between T#TS The reliability of T#TS joint is very much essential to ensure the safety of the equipments. TUBES There are two types of tubes Seam tube welded tube TUBESHEET It is the end plate of the shell on which tubes are welded in heat exchanger or any other heat transferring equipments. Tube sheets are made from plate or forging by machining, boring, drilling as per design requirement. The holes are normally to the tubes plates, parallel to each other and circular with smooth internal surface. Holes are set in tube sheet as per pitch.

Tubes

Tube sheet Pitch Distance between centers of the adjacent holes.

WELDING PROCESS
Semi-Automatic Gas Tungsten Arc Welding
The welding performed for the joining of U tubes to tube sheets is a GTAW process, by using the Semi-Automatic welding The difference between manual and automatic welding equipment is the welding time orientation i.e. the parameters are controlled by an automatic machine, which uses a non consumable tungsten electrode shilded with inert gas. The arc is installed between the tip of the electrode and work to melt the metal being welded, as well as the filler metal, when used. The shielding gas protects the electrode and the molten weld pool from atmospheric contamination, and provides the required arc characteristics. This process is also called as non consumable electrode welding or TIG welding, however, the AWS terminology for this process is GTAW. Basic components are common to all GTAW steups: Torch with water cool non consumable electrode Welding power source with high frequency unit Shielding gas A water cool welding torch is used when cooling from the inert Gas shield is inadequate.

Application of GTAW.
It produces superior quality welds, generally free of defects. It is free of spatter, which occurs with other arc welding process. It allows excellent control of root pass weld penetration. It can produce inexpensive autogeneous welds at high speed. It can use relatively inexpensive power supply and allows the precise control of the welding variables. It can be used to weld almost all material, including dissimilar metal joints. It allows the heat source and the filler metal additions to be controlled indepedently.

Welding parameters
Welding machine Fronius Mw2600 Welding process GTAW Shielding Gas Argon Purging Gas Argon Electrode ECWCe2 1.6 mm dia. Consumable SniCr20nb 0.6 mm dia (Er N-Ni Cr3) Polarity EN Volts 8 10 volts Peak current (A) 100A 120A Back current 25 A 35 A Travel speed 140 mm/min Flow rate 12 LPM Welding position clockwise Torch tilt angle 30 SADDLE SUPPORTS:-

Horizontal cylindrical vessels are supported on saddles. These are placed as two positions. If necessary the shell of vessel is strengthened by stiffeners located on the shell area surrounding the saddle. For large thin wall vessels or vessels under vacuum, it is necessary to provide ring supports. The location of the saddle support should be such that the distance from the tangent line to the centerline of the saddle should be less than the radius of the vessels.

Horizontal vessels resting on saddle supports behave as beams. They are subjected to longitudinal bending moments and local shear stresses due to the weight of the vessel. # PLATE TYPE # RING TYPE

METHODS :-

NONDESTRUCTIVE

EXAMINATION

Of the various conventional and advanced nondestructive examination (NDE) methods, five are widely used for the examination of pressure vessels and tanks by certified pressure vessel inspectors. The names and acronyms of these common five methods are: * VT Visual Examination, * PT Liquid Penetrant Test, * MT Magnetic Particle Test, * RT Gamma and X-ray Radiography, and * UT Ultrasonic Test. VT, PT and MT can detect only those discontinuities and defects that are open to the surface or are very near the surface. In contrast, RT and UT can detect conditions that are located within the part. For these reasons, the first three are often referred to as surface examination methods and the last two as volumetric methods. Table II of PUB 8-1.5 summarizes the main features of these five methods. VISUAL EXAMINATION (VT) :-

A visual examination is easy to conduct and can cover a large area in a short time. It is very useful for assessing the general condition of the equipment and for detecting some specific problems such as severe instances of corrosion, erosion, and hydrogen blistering. The obvious requirements for a meaningful visual examination are a clean surface and good illumination. LIQUID PENETRANT TEST (PT) :-

This method depends on allowing a specially formulated liquid (penetrant) to seep into an open discontinuity and then detecting the entrapped liquid by a developing agent. When the penetrant is removed from the surface, some of it remains entrapped in the discontinuities. Application of a developer draws out the entrapped

penetrant and magnifies the discontinuity. Chemicals which fluoresce under black (ultraviolet) light can be added to the penetrant to aid the detect ability and visibility of the developed indications. The essential feature of PT is that the discontinuity must be open, which means a clean, undisturbed surface. The PT method is independent of the type and composition of the metal alloy so it can be used for the examination of austenitic stainless steels and nonferrous alloys where the magnetic particle test is not applicable. MAGNETIC PARTICLE TEST (MT) :-

This method depends on the fact that discontinuities in or near the surface perturb magnetic flux lines induced into a ferromagnetic material. For a component such as a pressure vessel where access is generally limited to one surface at a time, the prod technique is widely used. The magnetic field is produced in the region around and between the prods (contact probes) by an electric current (either AC or DC) flowing between the prods. The ferromagnetic material requirement basically limits the applicability of MT to carbon and low-alloy steels. Applying fine particles of a ferromagnetic material to the surface reveals the perturbations of the magnetic lines. The particles can be either a dry powder or a wet suspension in a liquid. The particles can also be treated to fluoresce under black light. These options lead to variations such as the wet fluorescent magnetic particle test (WFMT). MT has some capability for detecting subsurface defects. However, there is no easy way to determine the limiting depth of sensitivity since it is highly dependent on magnetizing current, material, and geometry and size of the defect. A very crude approximation would be a depth no more than 1.5 mm to 3 mm (1/16 in to 1/8 in). A very important precaution in performing MT is that corners and surface irregularities also perturb the magnetic field. Therefore, examining for defects in corners and near or in welds must be performed with extra care. Another precaution is that MT is most sensitive to discontinuities, which are, oriented transverse to the magnetic flux lines and this characteristic needs to be taken into account in determining the procedure for inducing the magnetic field. RADIOGRAPHY (RT) :-

The basic principle of radiographic examination of metallic objects is the same as in any other form of radiography such as medical radiography. And basic useful industrial radiography in use two type of sourse:x-ray gamma ray(Iridium-192,cobalt-60,etc.,) Holes, voids, and discontinuities decrease the attenuation of the X-ray and produce greater exposure on the film (darker areas on the negative film). Because RT depends on density differences, cracks with tightly closed surfaces are much more difficult to detect than open voids. Also, defects located in an area of a abrupt dimensional change are difficult to detect due to the superimposed density difference. RT is effective in showing defect dimensions on a plane normal to the beam direction but determination of the depth dimension and location requires specialized techniques. Since ionizing radiation is involved, field application of RT requires careful implementation to prevent health hazards.

ULTRASONIC TESTING (UT) The fundamental principles of ultrasonic testing of metallic materials are similar to radar and related methods of using electromagnetic and acoustic waves for detection of foreign objects. The distinctive aspect of UT for the inspection of metallic parts is that the waves are mechanical, so the test equipment requires three basic components. * Electronic system for generating electrical signal. * Transducer system to convert the electrical signal into mechanical vibrations and vice versa and to inject the vibrations into and extract them from the material. * Electronic system for amplifying, processing and displaying the return signal. Very short signal pulses are induced into the material and waves reflected back from discontinuities are detected during the receive mode. The transmitting and detection can be done with one transducer or with two separate transducers (the tandem technique). Unlike radiography, UT in its basic form does not produce a permanent record of the examination. However, more recent versions of UT equipment include automated operation and electronic recording of the signals. Ultrasonic techniques can also be used for the detection and measurement of general material loss such as by corrosion and erosion. Since wave velocity is constant for a specific material, the transit time between the initial pulse and the back reflection is a measure of the travel distance and the thickness. HELIUM LEAK TESTS:-

The aim is have a heat exchanger with very high leak tight integrity. The helium leak test procedures used shall be of heighest achievable overall sensitivity, capable of detecting very small integrated and also local leakage rates as give below: Integrated leakage rates equal to or exceeding 10 -6 cc / sec shall not be acceptable. Local leakage rates equal to or exceeding 10 -7 cc / sec shall also not be acceptable. Integrated leakage rates for gaske5ted joints only may be permitted to exceed 10 -6 cc/sec provided the total leakage rates through the gasketed joints is within 10 -4 cc / sec. HYDROSTATIC TESTS:-

The heat exchanger shall be subjected to and shall withstand without damage, distortion or leakage, the hydrostatic test pressure for the specified time as per ASME code section 3 NB. The test temperature shall be sufficiently above the Nil ductility transition temperature. The hydrostatic test procedure shall be generally as per specification. To ensure the integrity of the vessel and system operation under pressure. Recommended for pressure vessel operating under pressure ensures the strength of weld joints and material. Ensure the nozzle flange joint. Test the strength of the vessel at 1.5 times the design pressure. Ensure safe and reliable performance during the operational life.

SAFETY DURING TESTING: -

Display red bulb at the enter point where RT is performing. RT should be far away from the place where people are working. The area should be covered by the specific instruction in radiographic testing.. Only permitted person should perform the radiographic testing. Grinding, welding or other processes should not performed nearby where liquid penetrate test is performed because acetone and cotton waste are inflammable material. Testing area should be covered by the thick wall in RT. Make proper arrangement for the fresh air while working in the confined space because acetone is immediately evaporate and cause of suffocation. Assembly:-

Assembly means join two or more parts for get final job. The part is joined for get final assembly is known as sub-assemblies the sub-assemblies are finally made in various shops and complete with inspection and checking. Heat treatment Introduction During fabrication material under goes different process such as welding, rolling, machining etc. in this type of process stresses is developed in material and remains as a residual stress. Due to this phenomena bearing capacity of material is reduced. To remove this type of residual stresses heat treatment is to be carried out. Heat treatment may be define as an operation involving the heating of solid metals to definite temperature followed by cooling at suitable rates in order to obtain certain physical properties which are associated with change in the nature from size and distribution of the micro-constituents. Heat treatment is to achieve one or more of the following objective. To relieve internal stresses set up during cold-working casting welding and hot working operations. To improve machinability To change grain size To improve mechanical properties FINAL INSPECTION AND PAINTING:-

After hydro test final inspection is done because some defects may be occur during hydro test After final inspection job is released for painting Painting is done as per customer requirement as per nature of service condition After painting job is not directly lift by crane suitable wooden and other packing is required for eliminate scratches and other defects on completed job. Handling:-

Before handling a war reserve vessel in a manned area, the responsible designer or Responsible Individual must verify that the equipment is not pressurized

at over its room temperature MAWP. Certification of the charged pressure from the supplier is normally required. Identification of the person responsible for the charge pressure and the method for confirming it must be included in the ESN. If the vessel or assembly cannot be approved for manned-area operation, it must be enclosed in a containment vessel (see Section 5.0 of this document for details) or have the charge pressure reduced to an acceptable level before transport to LLNL. A Heat exchanger is a closed, rigid, container designed to hold gases or liquids at a pressure and temperature different from the ambient pressure. In the industrial sector, Heta exchangers are designed to operate safely at a specific pressure and temperature, technically referred to as the "Design Pressure" and "Design Temperature". A vessel that is inadequately designed to handle a high pressure constitutes a very significant safety hazard. Because of that, the design and certification of pressure vessels is governed by design codes such as the ASME Boiler and Pressure Vessel Code (BPVC) in North America, the Pressure Equipment Directive of the EU (PED), Japanese Industrial Standard (JIS), CSA B51 in Canada and other international standards very usuful code of heat exchanger is TEMA and API Generally Heat Exchanger Design Codes:Most of the pressure or storage vessels in service in the United States will have been designed and constructed in accordance with one of the following two design codes:s The ASME Code, or Section VIII of the ASME (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code; or The API Standard 620 or the American Petroleum Institute Code which provides rules for lower pressure vessels not covered by the ASME Code. In addition, some vessels designed and constructed between 1934 and 1956 may have used the rules in the API-ASME Code for Unfired Pressure Vessels for Petroleum Liquids and Gases. This code was discontinued in 1956. Trained inspectors qualified for each code can only perform vessels certification. Written tests and practical experience are required for certification. Usually, the compliance office is not equipped for this task, but is able to obtain the necessary contract services.