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Heat exchangers are located within the conventional process unit plot area, close to

related equipment, to support economic pipe runs, flexibility , process requirement and
operator & maintenance access. Support of the equipment (eg for air coolers or vertical
reboilers) can also influence heat exchanger location.
Figure 8 depicts a typical plot plan with several heat exchanger applications. Horizontal
shell & tube exchangers should be positioned so that the channel end faces the auxiliary
road or maintenance access way for tube bundle removal with adequate space provided
at the front end of the exchanger for bonnet removal. This is indicated in figure 9.
Exchangers can be located as single items , in pairs (this is the most common
installation) , or in larger groups when no intermediate control is required between the
shell & tube streams. The single and paired installation is shown in figure 10. Paired
exchangers may operate in series , parallel or dissimilar services; grouped exchangers
operate only in series or parallel. Fig. 11 shows samples of parallel and series
exchanger installations.
Paired or grouped exchanger should be spaced to allow a minimum 450mm between
the outside of adjacent channel or bonnet flanges to facilitate access to flange bolts for
maintenance. Space should be provided on either side of paired exchangers and at both
end s of grouped exchangers for control & operator access. Fig 12 illustrates a structure
mounted installation & its required access areas.
Horizontal exchangers may be stacked to a preferred maximum top shell centerline of
3600 mm from grade or platform as indicated in fig.13. Stacking of exchangers above
this height may require platforming for access to channel and bonnet flanges and fixed
handling devices.
Horizontal shell & tube exchangers may be located at grade or elevated in steel or
concrete structures when process requirements or space availability dictate. Fig 14
indicates support of horizontal exchangers is by saddles attached to concrete piers.
If process requirements permit, shell & tube exchangers can also be mounted in a
vertical position, supported by lugs and tower nozzles in a tower supported installation
(as shown in fig.15), and within concrete or steel structures ( as shown in fig.16). The
same considerations for maintenance , control and operator access should be given for
vertical installations as are for horizontal installations.
Tube bundle removal for Tower supported vertical reboilers , not requiring springs, is
indicated in figure 16a.
1. the layout designer must set the reboiler support lug elevation 25 mm above the
platform steel, and not at the steel elevation.
2. Before maintenance, the 25 mm gap will be shimmed, thereby enabling the reboiler
load to be carried by the platform steel during maintenance turnaround.
3. The nozzle and channel flange will be unbolted and the channel section removed.
4. The tube bundle is then ready to be removed.
Spiral & plate exchnagers can operate in series or parallel , but because of their
configuration and maintenance requirements, it is preferable to position them as single
items. Space is provided at both arrangements for control & operator access , with
enough room allowed at the spiral exchanger to swing the cover plates open , as shown
in fig.17 and at the plate exchanger to remove the individual plates , as shown in fig. 18.
Air coolers are located adjacent to the equipment that they serve for piping flexibility &
maintenance. They can be supported from grade, at the top of structure, or above
piperacks , which is the most common installation.

5.0 CONSIDERATIONS FROM PIPING POINT OF VIEW

Nozzle orientation & location can affect the piping configurations at most exchanger
arrangements. A decision by the piping designer to relocate the exchanger nozzles can
often produce a neat and cost effective arrangement.
Although the piping designer does not have the freedom to independently relocate the
exchanger nozzles , suggested alternate nozzle locations can be made to the
exchanger engineer in the interest of improving piping arrangements , for example,
alternative B is fig. 19 highlights an improved arrangement by relocating exchanger
nozzles provided is acceptable from process point of view. Fig. 20 shows allowable
nozzle configurations. Elbow nozzles (see fig. 21) are especially helpful in reducing the
height of large stacked exchangers.
Exchanger Piping must be routed in such a manner that it meets economy., flexibility,
support and operation and maintenance access requirements. Piping at shell & tube
exchangers is positioned to allow adequate space for removal of channel heads and
shell covers. The free space at the side of horizontal shells can be used for placement of
controls. Piping is elevated a minimum distance from grade or platform to provide
operator headroom clearances, to offer ease of support, and to meet designed pipe
rack elevations.
Piping connected to channel head nozzles should be furnished with break flanges to
facilitate the removal of channel head. Large diameter or more expensive pipe can not
be set to accommodate smaller or less expensive piping
Piping at spiral and plate exchangers is also positioned to allow the opening of covers
and the removal of plates. Control at the spiral exchanger are located on the ends of the
unit, clear of the cover plate swing area , and at the front and on one side for the plate
exchanger. Piping is elevated similar to shell & tube exchanger. Piping attached to cover
plate nozzles of the spiral units is furnished with break flanges.
Figures 22 to 29 indicates various piping configurations for heat exchangers.
The internals of heat exchangers requires periodic cleaning and repair. It is important
that exchangers are positioned in a such a way as to facilitate access to their internal
parts.
For shell & tube exchangers, the tubes & interior of the shell can be cleaned in place
with high pressure steam or water and rodding devices. If the design of the exchangers
permits, the tube bundle can also be removed for repair & cleaning. Tube bundles and
head and shell covers can be removed by built in fixed handling devices (davits, pulling
posts), fixed structures with trolley beams, or by mobile equipment (eg. Crane). Figure
30 to 32 gives examples of tube bundle removal equipment.
Areas for tube maintenance and bundle pulling shall be shown on plot plan and may
extend over access ways within a unit area or over peripheral roads which are not
required for access to other plants. The extent of the pulling area shall be head length +
tube length + 1500mm preferable. ( but 1000 mm minimum.)
Equipment such as condensers, coolers etc shall be located in such a manner that the
tubes will drain clear by gravity and shall only be sloped where shown on P&I diagrams.
Where this slope will prevent the tubes draining by gravity consideration must be given
to the means of removing any liquids.

6.0 KEY FACTORS TO BE CONSIDERED DURING DESIGN


1. Exchanger Piping must be routed in such a manner that it meets economy., flexibility,
support and operation and maintenance access requirements.
2. Piping connected to channel head nozzles should be furnished with break flanges to
facilitate the removal of channel head.
3. Piping attached to cover plate nozzles of the spiral units is furnished with break
flanges.

4. Large diameter or more expensive pipe can not be set to accommodate smaller or
less expensive piping.
5. The internals of heat exchangers requires periodic cleaning and repair. It is important
that exchangers are positioned in a such a way as to facilitate access to their internal
parts.
6. Due consideration shall be given to stress analysis for deciding the fixed saddle
location of heat exchangers.

Fig 1 Types of Heat Exchangers

Figure 2
Shell & Tube Exchanger

Figure 3
Typ. Shell & Tube Exchanger Arrangements

Figure 4
Plate Exchanger

Figure 5
Spiral Exchanger

Figure 7
Double Pipe Exchanger

Figure 8
Typical Plot plan of exchanger Application

Figure 9
Exchanger Orientation

Figure 10
Single & Paired Exchangers

Figure 11
Parallel & Series Exchanger Installation

Figure 12
Structure Mounted Exchanger Installation

Figure 13
Stacked Exchanger Installation

Figure 14
Typical Horizontal Exchanger Supports

Figure 15
Tower Supported Vertical Installation

Figure 16
Structure Supported Vertical Installation

Figure 16a
Tube Bundle Maintenance

Figure 17
Control & Operator Access in a Spiral Exchanger Arrangement

Figure 18
Control & Operator Access in a Plate Exchanger Arrangement

Figure 19
Alternative arrangement for locating exchanger nozzles

Figure 20
Allowable Nozzle Configurations

Figure 21
Effect of Elbow Nozzles on Stacked Exchangers

Figure 22
Piping Arrangement for Horizontal Shell & Tube Exchangers

Figure 23
Piping Arrangement for Underground Cooling water system

Figure 24
Sample Piping Economy Arrangement

Figure 25
Supports for a Piping Arrangement

Figure 26
Piping Arrangement for High Temperature, High Pressure Feed Exchangers

Figure 27
Piping Arrangement for Feed Exchangers

Figure 28
Piping Arrangement for Spiral Exchangers

Figure 29
Piping Arrangement for Plate Exchangers

Figure 30
Bundle Pulling

FIXED STRUCTURE WITH TROLLEY BEAM

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