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#: PAR-MCR-PROCESS/
Training Manual-01
PROCESS TRAINING MANUAL Issue # 01 Issue Date:
HEAT EXCHANGERS & FIN FAN COOLERS Page 1 of 38 01-07-2005
CHANGE RECORD
Contents
13.1. HEAT TRANSFER
13.2. TYPE OF HEAT TRANSFER
13.2.1. Convection Heat Transfer
13.2.2. Conduction Heat Transfer
13.2.3. Radiation Heat Transfer
13.3. EQUIPMENT FOR HEAT EXCHANGE
13.4. HEAT EXCHANGERS
13.5. MECHANICS OF HEAT TRANSMISSION
13.6. TYPES OF HEAT EXCHANGER
13.7. EXCHANGER OPERATION AND MAINTENANCE
13.8. FIN FAN COOLERS
13.9. MCR EXCHANGERS LIST & DATA
In the petroleum refining, the proper use of heat is extremely important and
successful operation of petroleum processes is largely dependent upon correct heat
application.
Crude oil is separated into its various products by boiling. Heat is applied to the oil in
heaters from which it passes to the distillation columns where the products or
fractions are separated and taken off.
To supply the heat required, large quantities of fuel must be burned in the heaters
and any reduction in the amount of fuel used is a saving in refinery operation costs.
Any heat which has been given to the oil and is not used, is a waste to fuel, thus the
conversation and full usage of heat is a major part of refinery operation.
As the oil entering the plant is usually cold, and products leaving the various
columns are hot and need to be cooled before going to storage, we conserve by
transferring the heat in the products to the incoming oil.
By this means the oil going to the heater is hotter and therefore less fuel is required
to bring it up to its required temperature.
In the refinery to do this we use equipment called heat exchangers. These devices
provide a practical means of adding or removing heat at various points in a process.
The heat transfer methods of convection, conduction and radiation are the three
fundamental types when considering the transfer mechanism and may occur at the
same time.
Convection is the transfer of heat from one part to another within a fluid, gas or
liquid, by the mixing of one portion of the fluid with another.
Convection heat transfer is further divided into natural convection where the motion
of the fluid entirely depends upon the difference in density, in other words, the
difference in temperature and forced convection where the motion of the fluid is
caused by mechanical force.
The speed of forced convection is, of course, faster than that of natural convection.
Typical example:
Conduction is the transfer of heat from one part of a body to another part of the
same body, or from one body to another in contact, without any mixing of each of
the components.
This heat transfer is the result of transfer of the momentum of atoms and / or
molecules.
Typical example:
The handle of a teaspoon in a cup of hot tea becomes warm after some time.
Radiation is the transfer of heat from one body to another, not by contact, but by
means of electromagnetic waves through space.
Every body emits electromagnetic waves depending upon its surface temperature.
When one body receives electromagnetic waves from another body, the
electromagnetic wave turns into heat (thermal energy).
Typical examples:
In this case, heat (energy) which is released by convection and radiation during the
combustion process of fuel is used directly to heat or vaporize a product. Examples
of this are steam boilers and furnaces (heaters).
In this case the heat transfer occurs by means of conduction or convection and no
combustion takes place. Examples of this are coolers, condensers and heat
exchangers.
This lesson covers the second type of heat exchangers, of the non fired type, in
detail.
A heat exchanger is the equipment used to exchange heat between two fluids with
different temperature, through a fixed wall, without mixing the two fluids.
Heat exchangers are widely used in refineries and chemical plants to:
Material wall between the fluids must have a high thermal conductivity.
Must be corrosion resistive.
Ratio of heat transfer area to fluid volume must be as large as possible.
Fluid flow rate must be as fast as possible.
Turbulence rate of fluid must be as high as possible.
Q = U, A, tm.
As can be seen from the equation, the higher the thermal conductivities and the
higher the temperature difference (driving force) and surface area of tubes, the
greater will be the quantity of heat transferred is given time.
In a heat exchanger, two fluids flow against the opposite sides of a wall, which
separate them. The fluids never come in contact with each other. Heat is passed
from the hot fluid to the cold fluid. The temperature of the hot fluid is reduced by
transferring heat to the other fluid.
The shell and tube exchanger is the most commonly used heat exchanger. Figure 1
shows the arrangement of heat exchanger tubes. It is desirable to place as many
tubes as possible in a heat exchanger. These tubes are available in different sizes.
Tubes are made of steel, copper, brass or alloys. Tubes are attached to a tube sheet
generally made of the same material,
Figure (2) shows an end view of the tube sheet. Tubes are attached by welding,
brazing or rolling. The tubes may also be attached by using packing glands. The
sizes, type and number of tubes depend on the amount and characteristics of the
fluid being handled.
Special care must be taken to prevent leakage between the tube sheet and the tube.
Holes are drilled in the tube sheet. These holes are only slightly larger than the
outside diameter of the tubes.
Specialized equipment is then used to expand the tube to fit the hole. This
expanding and rolling equipment is highly specialized and its use is usually left to
specialists.
If a leak free joint is not made, the tube fluid and the shell fluid will mix, which is
undesirable. Either under rolling or over rolling the tubes can cause leaks.
The tubes and tube sheets together are called the tube bundle. The tube bundle is
installed as a single unit. The bundle is also removed as a unit for inspection,
cleaning and repair.
Most heat exchangers contain baffles. Baffles are usually metal sheets placed
perpendicular to the tubes. These metal sheets cause the fluid to flow back and
forth across the tube bundle to get better heat transfer.
The baffles also give support to the tubes. The baffles are usually attached to the
outer shell of the heat exchanger. Figure (3) shows a segmental baffle. These
baffles have tubes running through them.
They help to route the fluid flow outside of the tubes. These baffles alternate
between the top and bottom of the shell. The arrows indicate fluid flow direction
around the tubes. In this diagram, very few tubes are shown. There are many more
tubes in a tube bundle.
Figure (4) shows a disc and doughnut baffle arrangement. The disc support tubes
but does not attach to the exchanger shell. The doughnut portion of the baffle
supports tubes and also attaches to the exchanger shell.
The simplest type of construction for a shell and tube heat exchanger is known as
the fixed tube sheet type. This is shown in figure (5). The fluid which will flow inside
the tubes enters the exchanger in the upper left hand part of the exchanger marked
IN
A partition forces the fluid to flow through the upper tubes toward the right hand
part of the exchanger. A partition on the right hand side of the exchanger causes the
fluid to flow back through tubes to the left middle section of the exchanger.
Legend:
A second partition on the left side of the exchanger forces the fluid to travel back to
the right side of the exchanger. The fluid returns to the left side of the exchanger
and leaves the exchanger in the outlet marked OUT.
Since the fluid flows back and forth throughout the exchanger, this exchanger is
known as a multi-pass fixed tube heat exchanger. The cooling fluid, usually water,
enters the exchanger at the inlet marked IN in the lower right hand portion of the
exchanger.
The baffle aid in circulation of the cooling water. The water leaves the exchangers at
the top of the exchanger. Both ends of the tube bundle are rigid and fixed. This
allows for very little expansion of the tubes. This heat exchange is only used where
the temperature difference between the two fluids is very small.
Figure (6) shows a U tube heat exchanger. The tubes in this exchanger are bent in
the form of a U. This design allows for large amounts of tube expansion but makes
it difficult to clean out tubes if they get clogged.
Legend:
Cooling water
Head
A538
Product
U-Tube Type
Figure (7) shows a floating head removable tube bundle exchanger. This type of
exchanger is standard for oil refinery use. Oil flows through the shell of the
exchanger. Oil enters the shell inlet nozzle. It is directed back and forth across the
tube bundle using segment baffles.
The oil leaves through the shell outlet. Cooling water enters the exchanger through
the channel inlet. The water flows through the tubes in the lower half of the channel
because of the partition plate. It then reverses direction and flows through the
channel outlet. This heat exchanger has a single pass shell and two pass tubes.
Figure (8) shows the details of the tube bundle used in the floating head exchanger.
The fixed tube sheet is larger than the floating tube sheet. This allows the floating
tube sheet to be slipped into the shell for ease of installation and removal. The fixed
tube sheet fits against the exchanger shell. The channel section is then bolted to this
tube sheet.
The end remains fixed and unable to move. This is shown in figure (9). The floating
head tube cover is removable. This cover allows easy removal of the tube bundle
and easy access for cleaning.
Figure (10) shows a detail of a tube sheet and floating head cover. Its function is to
direct the flow of the cooling water in the exchanger. Gaskets are used to make a
leak proof connection between the floating head and the tube sheet. The partially
assembled unit is shown in figure (11).
Leaky tubes or gaskets allow the two fluids to mix. Fouled tubes cause inefficient
heat transfer. For continuous and efficient operation, the exchanger must be as
clean as possible and free of leaks. The baffles must also be in good condition and
properly fitted.
Tubes may also become loose in the tube sheet. Vibration can cause the loosening
of tubes in the tube sheet. Applying hot fluid to a cold exchanger may cause thermal
expansion and the loosening of tubes. A large difference in pressure on the inside
and outside of the tubes may also cause the thin, walled tubes to collapse.
The heat exchangers are designed to operate completely full of fluid. Unequal heat
exchange results form either of the two fluid capacities being less than full.
When rotating tube cleaners are used, the inside surface of the tubes may be worn
thin or cut. They may also be bent or dented if they are cleaned on the outside.
Sand blasting or hydro blasting can wear away the metal if used too long.
Pressure tests and leak tests can be used to check the tubes in a bundle. A pressure
test consists of filling the exchanger with liquid or air to a pressure higher than
atmosphere pressure. A loss of pressure after a period of time will indicate a leak.
Leaky tubes may be re-rolled if they are leaking at the tube sheet. If only a few
tubes are leaking some where in the middle of the tube, they may be plugged. In
this case a tapered metal plug is driven into each end of the tube. The plugging of a
few tubes in a tube bundle and putting the exchanger back in service is not
uncommon.
This may be repeated until the number of tubes plugged interferes with efficient
exchanger operation.
On floating head exchangers, a special test ring is available which will test individual
tubes for leaks. Pressure is applied to the unit. A loss of pressure will indicate leaky
tube. Remember that any pressure testing may be dangerous.
All personnel not involved in the test should remain away from the test area. Only
qualified personnel should be allowed to pressure test an exchanger or be allowed in
the test area.
Shell and tube exchangers of the types previously described can be used for any of
the functions mentioned at the beginning of the test i.e. cooling, condensing
evaporation (re-boiling) etc.
It should be pointed out at this stage that the fundamental difference between a
shell and tube exchanger used as a condenser or a cooler is that in a condenser a
change of phase occurs (vapor to liquid) and therefore there should be little or no
temperature difference.
In other words Latent Heat is being withdrawn from the hot fluid.
In a cooler the fluid temperature does drop due to the removal of the hot fluids
sensible heat.
Figure (12)
This design is frequently found as heating units at the base of distillation columns.
In this type, liquid is vaporized in the shell (space around the tubes) using steam or
other hot material passing through the tubes.
An overflow baffle makes sure that tubes are always submerged in the liquid. The
vapors, given off during the heating, can be returned to the distillation column.
In some cases, due to location or climate it is not always possible to take cooling
water from the surroundings, due to either no water being available or the
temperature limitations of the supply / return may be a constraint.
The hot fluid is passed through the tubes and cooled by air passes over the tubes at
a high velocity by either a forced or an induced draft.
An air piping system is not required, and there is no limit to the air supply
volume.
There is practically no fouling on the outside surfaces of the tubes.
It is economical and easily maintained.
However, it also has the disadvantage where the minimum cooling level is limited by
ambient temperature.
For this reason air coolers are normally confined to Low Grade cooling.
The effective cooling surface of the tubes is enlarged by installing thin plates or fins
to the tubes to create better heat transfer.
During warm periods it is common in refineries to direct a fire water spray on to the
fin tubes which increases the fin fan capacity for heat removal due to the cooling
effect of the evaporating water.
21 100-E22 Steam / Air Preheater Air MP Steam 6.00 13.00 260.00 300.00 _ _ _ _ _
Sr. Service Design Press. Design Temp. Opr. Press. Opr. Temp.
Tag No. Description Type
No. T/S (Kg/cm) (C) (Kg/cm) (C)
3 100-EA4 Crude Column Condenser Overhead Vapors 3.5 / FV 143 / 115 _ _ Finned
Service Design
Sr. Design Temp. Opr. Press. Opr. Temp.
Tag No. Description Press. Type
No. (C) (Kg/cm) (C)
T/S (Kg/cm)
3 110-EA3 HVGO Product Cooler HVGO Product 24.00 191.00 _ _ Finned Tube
Tempered Water
4 110-EA4 Tempered Water 7.8 / FV 120 / 85 _ _ Finned Tube
Cooler
Stripper Diesel
Bottoms/Diesel H.C Stripper Pump 197 / 316 /
10 284-E11 22.10 14.80 259.00 344.00 15.70 5.89 Tubular
Pump around BTM around 231 247
Exchanger (H.C)
H.C Back Tempered 66 /
11 284-E12 Backwash Cooler 9.80 7.80 182.00 120.00 6.16 4.50 154 / 85 Tubular
Wash Oil Water 85
Product Fractionator
BFW & MP PF BTM 300 / 121 / 321 /
12 284-E13 Bottoms MP Steam 45 / FV 67.10 349.00 11.90 35.00 Tubular
Steam (H.C) 194 194 213
Generator
284- Cooling 34.5
13 Lean Amine Cooler Lean Amine 27.50 18.40 120.00 120.00 16.10 4.50 61.43 Tubular
E18A/B Water / 45
Distillate Pump Distillate
MP Steam 15.5 / 225 / 260 / 194 /
14 284-E50 around/MP Steam Pump around 15.30 290.00 12.50 14.00 Tubular
Generator FV 195 212 194
Generator (H.C)
Distillate
Distillate Product/LP BFW & LP 260 / 121 / 230 /
15 284-E52 Product 7 / FV 10.50 260.00 4.70 8.33 Tubular
Steam Generator Steam 156 156 169
(H.C)
284- Flash Fractionator FF OVHD Cooling 34.5
16 8.00 7.00 145.00 120.00 5.63 4.50 60 / 41 Tubular
E56A/B Trim Condenser Vap. Water / 45
Flash Fractionator
BFW & MP FF BTMs 15.5 / 225 / 194 / 383 /
17 284-E59 Bottoms/MP Steam 12.50 426.00 14.00 9.60 Tubular
Steam (H.C) FV 195 194 232
Generator
Distillate Product Cooling
18 284-E61 H.C Distillate 10.50 7.00 169.00 120.00 Hair pin
Trim Cooler Water
4 284-EA4 Diesel Product Cooler Diesel Product (H/C) 16.7 231 _ _ Finned Tube
Kerosene Pump
5 284-EA5 Kerosene Product (H/C) 11.2 223 _ _ Finned Tube
Around Cooler
Kerosene Product
6 284-EA6 Kerosene Product (H/C) 16.5 221 _ _ Finned Tube
Cooler
Product Fractionator
7 284-EA7 P.F BTM (H/C) 67.1 241 _ _ Finned Tube
Bottoms Cooler
Distillate Product
8 284-EA50 Distillate (H/C) 10.5 230 _ _ Finned Tube
Cooler
Flash Fractionator
9 284-EA51 FF OVHD Vapors (H/C) 8.0 170 _ _ Finned Tube
Condenser
Distillate Pump
10 284-EA54 Distillate (H/C) 15.3 240 _ _ Finned Tube
Around Cooler
Flash Fractionator
11 284-EA55 FF BTM (H/C) 12.5 260 _ _ Finned Tube
Bottoms Cooler
2 312-E2 Booster Gas Heater MP Steam Booster Gas 13.00 13.80 300.00 205.00 10.20 12.00 _ _ Hair Pin
3 312-E3 Caustic Cooler Caustic Cooling Water 12.30 8.20 120.00 120.00 6.80 4.50 43.00 34.50 Tubular
1 802-E1 Caustic Heater Caustic Steam 20.6 30.9 260 120 4.2 Hair Pin
2 802-E2 Lean Amine Trim Cooler Lean Amine Cooling Water 27.50 18.40 120.00 120.00 15.10 3.80 Hair Pin
Lean/Rich
820- 47.5 /
2 Solution Rich Amine Lean Amine 4.5 / FV 10.00 157.00 147.00 1.80 5.10 132 / 58 PLT/FR
E53 122
Exchanger
Lean
820- 56.5 /
3 Solution Lean Amine Cooling Water 9.00 7.00 120.00 120.00 5.30 3.80 34.5 / 45 PLT/FR
E54 41
Cooler