Handout HE Design

9/22/2014

1

MECHANICAL TEAM

September 24th, 2014

MECHANICAL TEAM

2

9/22/2014

2

Acquire basicbasicbasicbasic knowledgeknowledgeknowledgeknowledge about Heat exchanger

equipment, definition, function, classification and

correspondence to other discipline.

3

#1. There are two or more fluids

MECHANICAL TEAM

4

A HEAT EXCHANGER is a device that used to transfer thermal energy

(enthalpy) between two or more fluids, between a solid surface and a fluid,

or between solid particulates and a fluid, at different temperatures and in

thermal contact.

HEAT EXCHANGER characteristic :

WHAT ISWHAT ISWHAT ISWHAT IS HEAT EXCHANGER ?HEAT EXCHANGER ?HEAT EXCHANGER ?HEAT EXCHANGER ?

#2. There are temperature

differences, and

#3. In thermal contact

9/22/2014

3

MECHANICAL TEAM

5

1. Cooler : Reduce temperature

2. Heater : Increase temperature

3. Condenser : Remove heat from gas changing to liquid

4. Vaporizer : Add heat to liquid changing to gas

5. Re-boiler : Add heat to liquid changing to gas.

Usually used to provide heat for distillation column.

6. Chiller : Cooling liquid or gas using refrigerant.

WHAT IS FUNCTION OF HEAT WHAT IS FUNCTION OF HEAT WHAT IS FUNCTION OF HEAT WHAT IS FUNCTION OF HEAT EXCHANGER ?EXCHANGER ?EXCHANGER ?EXCHANGER ?

MECHANICAL TEAM

6

Source : Fundamental of heat exchanger design, Ramesh K. Shah, Dusan P. Sekulic

HEAT HEAT HEAT HEAT EXCHANGER CLASSIFICATIONEXCHANGER CLASSIFICATIONEXCHANGER CLASSIFICATIONEXCHANGER CLASSIFICATION

9/22/2014

4

Tubular Heat Exchanger

MECHANICAL TEAM

7

Characteristics :

“Generally built of circular tubes, although elliptical, rectangular, or round/flat twisted tubes have also been used in some applications”

Flexibility on the design because the core geometry can be varied easily by changing the tube diameter, length, and arrangement.

Has a wide range of design condition like pressure, temperature, material, fluid flow rate, etc., and high reliability.

These exchangers may be classified as :

1. Shell and Tube Heat Exchanger (STHE)

2. Double Pipe/Hairpin Heat Exchanger

3. Multitube Heat Exchanger

8

CODE AND STANDARD FOR DESIGNING

TUBULAR HEAT EXCHANGER

9/22/2014

5

MECHANICAL TEAM

9

1. Shell And Tube Heat Exchanger

Shell-and-Tube Heat Exchanger is an equipment where multipletubes (heat transfer tubes) are arrayed in the cylindrical shell andwhich performs the heat exchange among the fluids which flows oninner and outer surface of the tube.

MECHANICAL TEAM

10

SHELL

TUBESUPPORT

FRONT−END HEAD

REAR−END HEAD

BAFFLE

TUBESHEET

NOZZLE

9/22/2014

6

MECHANICAL TEAM

11

12

9/22/2014

7

MECHANICAL TEAM

13

Characteristic of Double Pipe HE :1. Usually consists of two concentric pipes.2. Used for small-capacity applications where

the total heat transfer surface area required is 10m2 or less.

3. It is not suitable for large surface area since as plot area becomes large.

2. Double Pipe/Hairpin Heat Exchanger

MECHANICAL TEAM

14

Characteristic of Multitube HE :

Combination of Shell-and-Tube Heat Exchanger and Double Pipe Heat Exchanger.

1. Surface area is larger than the double pipe heat exchanger.

2. It is suitable in the services double pipe heat exchanger can not handle.

3. Multi Tube Heat Exchanger

9/22/2014

8

MECHANICAL TEAM

15



16

1. Plate-fin

2. Finned Tube

Add secondary surface to increase area of heat transfer.

Extended Surface Heat Exchanger

EXTENDED

SURFACE

(Secondary

Surface)

Secondary surface (Fin)

9/22/2014

9

17

Air-cooled heat exchanger is an equipment which aims at cooling(or condensing) the gas, vapor and liquid of the process by using air ascooling medium.

Air Cooled Heat Exchanger

18

ON STRUCTURE(PIPE RACK)

ON FOUNDATION

9/22/2014

10

19

Air-cooled Heat Exchanger has following characteristicswhen compared with Shell-and-Tube Heat Exchanger.

1111.... AimAimAimAim isisisis alwaysalwaysalwaysalways totototo coolcoolcoolcool (or(or(or(or condense)condense)condense)condense) fluidfluidfluidfluid

2222.... HotHotHotHot fluidfluidfluidfluid alwaysalwaysalwaysalways flowsflowsflowsflows onononon thethethethe tubetubetubetube sidesidesideside.... TheTheTheThe airairairair alwaysalwaysalwaysalways flowsflowsflowsflows outsideoutsideoutsideoutside thethethethe

tubetubetubetube....

3333.... OnOnOnOn thethethethe airairairair sidesidesideside theretheretherethere isisisis alwaysalwaysalwaysalways 1111 passpasspasspass andandandand nononono bafflesbafflesbafflesbaffles....

4444.... AirAirAirAir flowflowflowflow raterateraterate isisisis decideddecideddecideddecided accordingaccordingaccordingaccording totototo thethethethe designer’sdesigner’sdesigner’sdesigner’s sensesensesensesense....

5555.... ACHEACHEACHEACHE comparedcomparedcomparedcompared withwithwithwith STHESTHESTHESTHE whenwhenwhenwhen qualitativelyqualitativelyqualitativelyqualitatively comparedcomparedcomparedcompared withwithwithwith coolercoolercoolercooler andandandand

condensercondensercondensercondenser ofofofof ShellShellShellShell----andandandand----TubeTubeTubeTube HeatHeatHeatHeat ExchangerExchangerExchangerExchanger whichwhichwhichwhich usesusesusesuses coolingcoolingcoolingcooling waterwaterwaterwater....

MECHANICAL TEAM

20



9/22/2014

11

21

PlatePlatePlatePlate−−−−typetypetypetype heatheatheatheat exchangersexchangersexchangersexchangers areareareare usuallyusuallyusuallyusually builtbuiltbuiltbuilt ofofofof thinthinthinthin platesplatesplatesplates (all(all(all(all primeprimeprimeprime surface)surface)surface)surface)....

TheTheTheThe platesplatesplatesplates areareareare eithereithereithereither smoothsmoothsmoothsmooth orororor havehavehavehave somesomesomesome formformformform ofofofof corrugation,corrugation,corrugation,corrugation, andandandand theytheytheythey areareareare

eithereithereithereither flatflatflatflat orororor woundwoundwoundwound inininin anananan exchangerexchangerexchangerexchanger....

Generally,Generally,Generally,Generally, thesethesethesethese exchangersexchangersexchangersexchangers cannotcannotcannotcannot accommodateaccommodateaccommodateaccommodate veryveryveryvery highhighhighhigh pressures,pressures,pressures,pressures,

temperaturestemperaturestemperaturestemperatures,,,, orororor pressurepressurepressurepressure andandandand temperaturetemperaturetemperaturetemperature differencesdifferencesdifferencesdifferences....

Plate Heat Exchanger

22

1. Plate and Frame Heat Exchanger

9/22/2014

12

MECHANICAL TEAM

23

24

2. Cold Box / Compabloc

9/22/2014

13

MECHANICAL TEAM

25

PROCESS DATASHEET

REVIEW OF PROCESS DATASHEET

STRENGTH CALCULATION AND

WEIGHT ESTIMATION

LOADING DATA

NOZZLE ORIENTATION DRAWINGNOZZLE LOAD

REQUISITION

PREPARE TBE

PO RELEASE

VENDOR DOCUMENT & DRAWING

INSPECTION &TEST RECORD

AS BUILT DRAWING

HEAT HEAT HEAT HEAT EXCHANGER EXCHANGER EXCHANGER EXCHANGER DESIGN WORK FLOWDESIGN WORK FLOWDESIGN WORK FLOWDESIGN WORK FLOW

PID

INPUT

Eng. Activity

OUTPUT

PREPARATION OF MECHANICAL DATASHEET

MECHANICAL DATASHEET

PREPARATION OF REQUISITION

VENDOR QUOTATION

TBE & CBE

REVIEW/APPROVE VENDOR

DOCUMENT AND

DRAWING

APPROVEDVENDOR

DOCUMENT AND DRAWING

IDC

KICK OF MEETING

FOLLOW UP DESIGN CHANGE

INSPECTION & TEST

26

Heat Exchanger INPUT DESIGN

PROCESS

PROCESS

PROCESS

PROCESS

& HSE

& HSE

& HSE

& HSE 1.1.1.1. Process DatasheetProcess DatasheetProcess DatasheetProcess Datasheet

2.2.2.2. Equipment Rating SheetEquipment Rating SheetEquipment Rating SheetEquipment Rating Sheet

3.3.3.3. Coating, Insulation and Fireproofing Requirement, Coating, Insulation and Fireproofing Requirement, Coating, Insulation and Fireproofing Requirement, Coating, Insulation and Fireproofing Requirement, etcetcetcetc

PIPING 1.1.1.1. Nozzle Orientation and ElevationNozzle Orientation and ElevationNozzle Orientation and ElevationNozzle Orientation and Elevation

2.2.2.2. Platform & Ladder requirement (if any)Platform & Ladder requirement (if any)Platform & Ladder requirement (if any)Platform & Ladder requirement (if any)

3.3.3.3. PipePipePipePipe Clip SupportClip SupportClip SupportClip Support

4.4.4.4. Pipe RackPipe RackPipe RackPipe Rack Dimension (Design ACHE Support)Dimension (Design ACHE Support)Dimension (Design ACHE Support)Dimension (Design ACHE Support)

INSTRUMENTINSTRUMENTINSTRUMENTINSTRUMENTVessel Instrument Sketch Vessel Instrument Sketch Vessel Instrument Sketch Vessel Instrument Sketch

Nozzle Size, Flange Rating, Nozzle Span & Elevation.Nozzle Size, Flange Rating, Nozzle Span & Elevation.Nozzle Size, Flange Rating, Nozzle Span & Elevation.Nozzle Size, Flange Rating, Nozzle Span & Elevation.

ELECTRICALELECTRICALELECTRICALELECTRICAL1.1.1.1. Electrical Load Specification (ACHE)Electrical Load Specification (ACHE)Electrical Load Specification (ACHE)Electrical Load Specification (ACHE)

2.2.2.2. EarthingEarthingEarthingEarthing Layout Layout Layout Layout

CIVILCIVILCIVILCIVIL Wind and Earthquake Design BasisWind and Earthquake Design BasisWind and Earthquake Design BasisWind and Earthquake Design Basis

9/22/2014

14

27

Heat Exchanger DESIGN OUTPUT

1. MECHANICAL DATASHEET / ENGINEERING DRAWING

1.1.1.1. Deliverable Document to ClientDeliverable Document to ClientDeliverable Document to ClientDeliverable Document to Client

2.2.2.2. Requisition Document to VendorRequisition Document to VendorRequisition Document to VendorRequisition Document to Vendor

3.3.3.3. Piping Basis to Develop 3D Piping Basis to Develop 3D Piping Basis to Develop 3D Piping Basis to Develop 3D

Model (Preliminary)Model (Preliminary)Model (Preliminary)Model (Preliminary)

4.4.4.4. Piping Basis to Develop Piping Piping Basis to Develop Piping Piping Basis to Develop Piping Piping Basis to Develop Piping

LayoutLayoutLayoutLayout

5.5.5.5. Basis Document to Review Basis Document to Review Basis Document to Review Basis Document to Review

Vendor DrawingVendor DrawingVendor DrawingVendor Drawing

28

2. VENDOR GA DRAWING


1.1.1.1. Piping Basis to Piping Basis to Piping Basis to Piping Basis to Update Update Update Update 3D Model 3D Model 3D Model 3D Model

2.2.2.2. Vendor Basis to Develop Vendor Basis to Develop Vendor Basis to Develop Vendor Basis to Develop

Fabrication DrawingFabrication DrawingFabrication DrawingFabrication Drawing

3.3.3.3. Construction Info for Determine Construction Info for Determine Construction Info for Determine Construction Info for Determine

Rigging StudyRigging StudyRigging StudyRigging Study

4.4.4.4. Etc.Etc.Etc.Etc.

STHE Vertical

9/22/2014

15

29

Definition :Definition :Definition :Definition :

1.1.1.1. No of Unit No of Unit No of Unit No of Unit = 1= 1= 1= 1

2.2.2.2. NoNoNoNo of Bay/Unitof Bay/Unitof Bay/Unitof Bay/Unit = 1= 1= 1= 1

3.3.3.3. No of Bundle/BayNo of Bundle/BayNo of Bundle/BayNo of Bundle/Bay ==== 2222

1 Bundle1 Unit

1 Bay

30

3. LOADING DATA


> HORIZONTAL > VERTICAL

> ON FOUNDATION > ON STRUCTURE

> FOUNDATION BOLT > SETTING BOLT

> TUBE BUNDLE REMOVABLE > TUBE BUNDLE NOT

REMOVABLE

9/22/2014

16

31

REMOVABLE BUNDLE OF STHE

EA-441

EA-217

Piping � Pulling Area at Plot Plant

Civil � Pulling Load of Bundle

32

9/22/2014

17

33

Plate Heat Exchanger (GASKETED) Plate Heat Exchanger (WELDED)

34

Battery Limit Scope of Supply

1. Piping � Nozzle flange (Bolt, nut, and gasket by Piping)� Pipe clip welded to equipment

1

1

1

2

Ladder or Platform

Mounted on Equipment By

Static

2. Civil � Base plate to foundation or Structure Support. Anchor bolt by??

Insulation By

Construction

.

3. Electrical � Earth Lug� Junction Box Motor (ACHE)

9/22/2014

18

35

SUMMARYSUMMARYSUMMARYSUMMARY

1. A HEAT EXCHANGER is a device that used to transfer thermal energy(enthalpy) between two or more fluids, between a solid surface and a fluid,or between solid particulates and a fluid, at different temperatures and inthermal contact.

2. Commonly used Heat Exchanger on Industrial Plant : STHE, ACHE, PFHE.3. STHE widely used as Heat Exchanger due to its flexibility of design and

operation.4. ACHE only aiming for cooling or condensing.5. Operation cost of ACHE is lower than STHE.6. Pulling area for removable bundle of STHE shall be clearly mentioned on

plot plant.7. Etc.

MECHANICAL TEAM

36

9/22/2014

19

37

38

9/22/2014

20

39

Documents

Handout HE Design