HAIRPIN

HEAT EXCHANGERS

KOCH HEAT TRANSFER COMPANY

KHT_Hairpin_new GMG.indd 1 2/9/11 4:21 PM

 CLOSER TEMPERATURE APPROACH
The Process Advantage
Hairpin heat exchangers utilize true counter-current flow. COUNTER CURRENT FLOW
Unlike multi-pass shell-and-tube designs where correction Shellside
factors are used to account for inefficiencies resulting from
co-current passes, this process maximizes temperature
differences between shellside and tubeside fluids. When
a process calls for a temperature cross (hot fluid outlet Tubeside
temperature is below cold fluid outlet temperature), a
hairpin heat exchanger is the most efficient design, with
fewer sections and less surface area. Double-pipe heat
exchangers utilize a single pipe-within-a-pipe design and
are commonly used for high fouling services such as slurries where abrasive materials are present, and
for smaller duties. Standard shell diameters range from 2” to 6”. Multi-tube heat exchangers are used for
larger duties with standard designs for shell diameters up to 30” and surface areas in excess of 10,000 ft2
per section. BROWN FINTUBE® hairpin heat exchangers offer a variety of unique enhancement devices for
different process conditions.

Shellside Enhancement Devices

 Longitudinal fintubes - Provide extended heat transfer surface with relatively low
resulting pressure drops. They can be cut-and-twisted or used in conjunction with
peripheral baffles for further enhancement.

 TWISTED TUBE® Technology - Simultaneously enhances both shellside and

tubeside heat transfer rates. They are self-supporting and allow straight-through
cleaning of the shellside, despite being on a triangular tube pitch. The risk of flow-
induced vibration is eliminated with this design and shellside fouling is minimized
due to the elimination of “dead” spots commonly found when traditional segmental
baffles are utilized.

 Low Pressure Drop LOK-BAFFLE™ Baffles - Act primarily as tube supports. These are
used for high shellside flow rates, low allowable pressure drops, or when the shellside
coefficient does not limit the overall heat transfer rate.

 Segmental baffles - These are traditional baffles that can be used in conjunction with
seal-strips.

KHT_Hairpin_new GMG.indd 2 2/9/11 4:21 PM

 HIGHER HEAT TRANSFER RATES
Tubeside Enhancement Devices
 TWISTED TUBE® Bundles - Promote turbulence of the tubeside fluid. They are also used for vaporizing services
and when tube inserts are not preferred.

 Tube Inserts - BROWN FINTUBE® technology offers a variety of tube inserts, which maximize the heat transfer
rates of viscous fluids. They are also used for vaporizing services.

KHT_Hairpin_new GMG.indd 3 2/9/11 4:21 PM

 EFFICIENCY IN DESIGN

Large Radius U-bends

The free-floating U-tube bundle compensates for the differential shell-tube expansion and eliminates the need
for expansion joints or packed joints commonly used in shell-and-tube type heat exchangers. Large radius
U-bends are easily cleaned with flexible shaft tube cleaners.

The Mechanical Advantage

1. Separate tubesheets: Handle high temperature differences and cycling more effectively than shell-and-tube
exchangers.
2. Durable baffle cage construction: Welded to the tie rods without the need for “sleeves” or internal nuts.
3. Moveable support brackets: Allow shell expansion and contraction and eliminate the need for sliding plates
commonly used for fixed supports. Brackets are slotted for anchor bolts on all four sides for flexibility in
installation, and offer the ability to add sections in the future.
4. Patented closure technology: Suits specific design needs (see adjacent page for details).
5. Tubeside and shellside connections on the same end: Easy installation and piping.
6. No internal bolting!
7. Double-pipe exchangers: Use pipe in lieu of thin wall tubing to enhance integrity.

KHT_Hairpin_new GMG.indd 4 2/9/11 4:21 PM

 CONVENIENT ACCESSIBILITY
Separated-Head Low Pressure Closure
Our separated-head closure uses independent tubeside and shellside flanges, bolting and gasketing. This closure
is used for moderate pressures up to 1,300 psi (92 kg/cm2), cyclic service, high temperature differences, and/or for
temperatures below -20°F (-28.8°C) or greater than 650°F (343°C).

TAPER-LOK® High Pressure Closure

Our TAPER-LOK® closure is typically used for high pressure up to 15,000 psi (1055 kg/cm2)
applications. Like our separated-head, the TAPER-LOK® closure uses separate tubeside
and shellside flanges, bolting and gasketing. The unique feature this closure offers is
a reusable TAPER-LOK® ring which acts as a self-energizing seal. Koch Heat Transfer
Company has an exclusive license for TAPER-LOK®
closures for use in double pipe and multi-tube hairpin
heat exchangers.

LOK-FLANGE® Closure
The LOK-FLANGE® closure uses common through-
bolting with independent gaskets and is typically used
for design pressures below 1,000 psi (70 kg/cm2). The
center flange of this closure is threaded, which allows
removal of the tube-end flange for inspection and
cleaning of the tubes while maintaining pressure on the
shellside. This closure allows the maximum number of
tubes in a given shell diameter.

ZR CLOSURE™ Closure
The ZR CLOSURE™ closure is the newest addition to
the BROWN FINTUBE® family of closures. This closure
bridges the gap between the separated-head and
the LOK-FLANGE® closure by providing separate tubeside and shellside flanging and
bolting, while retaining the maximum number of tubes in a given shell diameter.

Return End Bonnet Closure

This closure is a conservative through-bolted design. When the bonnet is removed, the
U-bends of the tubes are completely exposed to permit full field inspection.

Superior Closure Design

Our closure designs offer an effective means of providing a removable tube bundle for a variety of design conditions
and applications. All of our closures have the following features:
 External Split rings - Split rings are used to lock the bundle to the shell. On outdated models these rings were
internal and came into contact with the shellside fluid. Internal split-rings are still used by others.
 Through bolting - Earlier models used studded bolting that could seize or break off and are still used by other
manufacturers.
 Better gasketing - Unlike other manufacturers, our gaskets do not seat on the tubesheet face where
misalignment easily can occur and the potential for erosion exists. Our shellside gaskets are easier to remove
than wedge gasketing used by competitors.
 Separate tubeside and shellside gaskets - Prevent interstream leakage.
 Round flanges - More effective gasket seating than square flanges.

KHT_Hairpin_new GMG.indd 5 2/9/11 4:21 PM

 VARIETY OF SOLUTIONS
Exemplary Hairpin Applications
When To Use BROWN FINTUBE® Hairpin Heat Exchangers
A hairpin heat exchanger should be considered when one or more of
the following conditions exist:
 The process results in a temperature cross.
 High pressure tubeside application.
 A low allowable pressure drop is required on one side.
 Cyclic service.
 High flowrate ratios between shellside and tubeside fluids.
 High terminal temperature differences (300°F/149°C or greater).
 When an augmentation device will enhance the heat transfer coefficient.
 When the exchanger is subject to thermal shock.
 When flow-induced vibration may be a problem.
 When heating or cooling vapors.
 When complete vaporization is required.
 When solids are present in the process stream.
 When the mechanical advantages of a hairpin are preferred.

Koch Heat Transfer Company Maintenance Support

Maintenance
Operation and maintenance manuals are available that address the
disassembly and reassembly of specific designs. In general, the bundle of a
hairpin exchanger is removed by first removing the tubeside bolting, flanges
and split rings. The next step is to remove the shellside bolting, flanges and
split rings. Finally, the return bonnet bolting is removed and the bonnet is
placed to the side. The tube element can now be pulled from the back end
of the shell by placing a sling around the U-bends. On larger multitubes, a
plate is installed around the U-bend for proper sling placement. Assembly is
performed by reversing the process and utilizing new gaskets.

Spare Parts
Replacement parts for BROWN FINTUBE® or BAS-TEX exchangers are readily available. One complete set of gaskets is
recommended for one year’s operation.

Surveys
For facilities with numerous hairpin exchangers, Koch Heat Transfer Company
will perform a survey of the facility and establish design equivalents to current
BROWN FINTUBE® models. We will also evaluate ways to establish common
designs for multiple services to allow commonality of spare parts and elements,
resulting in reduced spare parts inventories and maintenance. Please contact a
Koch Heat Transfer Company sales representative for more details.

KHT_Hairpin_new GMG.indd 6 2/9/11 4:21 PM

 BROWN FINTUBE® is registered in the U.S. and other countries worldwide.
TWISTED TUBE® is registered in the U.S. and other countries worldwide.
LOK-FLANGE® is registered in the U.S.
Koch Heat Transfer Company is the sole supplier of BROWN FINTUBE® products.
TAPER-LOK® is a registered trademark of Taper-Lok Corporation.
Lummus Advanced Breech-Lock Exchanger™ is a registered trademark of Lummus Technology Heat Transfer.

KHT_Hairpin_new GMG.indd 7 2/9/11 4:21 PM

 KOCH HEAT TRANSFER COMPANY

For more information about our products and locations,

please visit our website

www.kochheattransfer.com
Email : info@kochheattransfer.com

KHT_Hairpin_new GMG.indd 8 2/9/11 4:21 PM

 KOCH HEAT TRANSFER COMPANY

GLOBAL
SOURCING
TWISTED TUBE®
EXCHANGERS TUBESIDE
AUGMENTATION

BROWN FINTUBE®
HAIRPIN EXCHANGERS TAPER-LOK®
CLOSURE
FINTUBE
TECHNOLOGY
BREECH-LOCK™
LOK-BAFFLE™ CLOSURE
LOW PRESSURE
DROP BAFFLES FLOW MODIFICATION
TECHNOLOGY
GLOBAL
MANUFACTURING

THE ONLY SOURCE YOU WILL NEED FOR HEAT TRANSFER SOLUTIONS.
Our thermal engineers rely on the Koch Heat Transfer Company state-of-the-art technologies
to develop the best possible solutions for our customers’ applications. From research and
development through thermal and mechanical design, best-in-class manufacturing, technical
assistance and aftermarket service, our engineers help you optimize your heat transfer systems
to make your operations more efficient and productive.

KHT_Hairpin_new GMG.indd 9 2/9/11 4:21 PM