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September 24th, 2014

MECHANICAL TEAM

MECHANICAL TEAM

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Acquire basic knowledge about Heat exchanger

equipment, definition, function, classification and
correspondence to other discipline.

WHAT IS HEAT EXCHANGER ?

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 :

#1. There are two or more fluids

#2. There are temperature
differences, and
#3. In thermal contact

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WHAT IS FUNCTION OF HEAT EXCHANGER ?

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.

MECHANICAL TEAM

HEAT EXCHANGER CLASSIFICATION

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

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Tubular Heat Exchanger

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

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CODE AND STANDARD FOR DESIGNING

TUBULAR HEAT EXCHANGER

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1. Shell And Tube Heat Exchanger

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

MECHANICAL TEAM

SHELL
NOZZLE
REAREND
HEAD

BAFFLE
FRONTEND
HEAD

TUBE
SUPPORT

TUBESHEET
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2. Double Pipe/Hairpin Heat Exchanger

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.

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3. Multi Tube Heat Exchanger

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

Characteristic of Multitube HE :
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.

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HEAT EXCHANGER CLASSIFICATION

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

MECHANICAL TEAM

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Extended Surface Heat Exchanger

Add secondary surface to increase area of heat transfer.

1. Plate-fin

Secondary surface (Fin)

2. Finned Tube
EXTENDED
SURFACE
(Secondary
Surface)
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Air Cooled Heat Exchanger

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

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ON STRUCTURE
(PIPE RACK)

ON FOUNDATION

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Air-cooled Heat Exchanger has following characteristics

when compared with Shell-and-Tube Heat Exchanger.
1. Aim is always to cool (or condense) fluid
2. Hot fluid always flows on the tube side.
side. The air always flows outside the
tube.
tube.
3. On the air side there is always 1 pass and no baffles.
baffles.
4. Air flow rate is decided according to the designers sense.
sense.
5. ACHE compared with STHE when qualitatively compared with cooler and
condenser of ShellShell-andand-Tube Heat Exchanger which uses cooling water.
water.

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HEAT EXCHANGER CLASSIFICATION

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

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Plate Heat Exchanger

Plate
Platetype heat exchangers are usually built of thin plates (all prime surface).
surface).
The plates are either smooth or have some form of corrugation, and they are
either flat or wound in an exchanger.
exchanger.
Generally, these exchangers cannot accommodate
temperatures,, or pressure and temperature differences.
temperatures
differences.

very

high

pressures,

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1. Plate and Frame Heat Exchanger

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2. Cold Box / Compabloc

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HEAT EXCHANGER DESIGN WORK FLOW

INPUT

PID

NOZZLE ORIENTATION DRAWING

NOZZLE LOAD

KICK OF MEETING

REVIEW OF PROCESS
DATASHEET

Eng. Activity

VENDOR DOCUMENT &

DRAWING

VENDOR QUOTATION

PROCESS DATASHEET

PREPARE
TBE

INSPECTION &
TEST
REVIEW/
APPROVE
VENDOR
DOCUMENT
AND
DRAWING

STRENGTH
CALCULATION AND
WEIGHT ESTIMATION

FOLLOW UP
DESIGN
CHANGE

IDC

OUTPUT

PREPARATION OF
MECHANICAL DATASHEET

PREPARATION OF
REQUISITION

APPROVED
VENDOR
DOCUMENT AND
DRAWING

TBE & CBE

MECHANICAL DATASHEET
LOADING DATA
REQUISITION

PO RELEASE

AS BUILT
DRAWING

INSPECTION &TEST
MECHANICAL
TEAM
RECORD

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PROCESS
& HSE

1.
2.
3.

Process Datasheet
Equipment Rating Sheet
Coating, Insulation and Fireproofing Requirement, etc

PIPING

Heat Exchanger INPUT DESIGN

1.
2.
3.
4.

Nozzle Orientation and Elevation

Platform & Ladder requirement (if any)
Pipe Clip Support
Pipe Rack Dimension (Design ACHE Support)

INSTRUMENT

Vessel Instrument Sketch

Nozzle Size, Flange Rating, Nozzle Span & Elevation.

ELECTRICAL

1. Electrical Load Specification (ACHE)

2. Earthing Layout

CIVIL

Wind and Earthquake Design Basis

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Heat Exchanger DESIGN OUTPUT

1. MECHANICAL DATASHEET / ENGINEERING DRAWING

1.
2.
3.

Deliverable Document to Client

Requisition Document to Vendor
Piping Basis to Develop 3D
Model (Preliminary)
4. Piping Basis to Develop Piping
Layout
5. Basis Document to Review
Vendor Drawing

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Heat Exchanger DESIGN OUTPUT

2. VENDOR GA DRAWING

1. Piping Basis to Update 3D Model

2. Vendor Basis to Develop
Fabrication Drawing
3. Construction Info for Determine
Rigging Study
4. Etc.

STHE Vertical

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1 Unit
1 Bundle

Definition :
1. No of Unit
2. No of Bay/Unit
3. No of Bundle/Bay

=1
=1
=2

1 Bay

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Heat Exchanger DESIGN OUTPUT

3. LOADING DATA

>
>
>
>

HORIZONTAL
ON FOUNDATION
FOUNDATION BOLT
TUBE BUNDLE REMOVABLE

> VERTICAL
> ON STRUCTURE
> SETTING BOLT
> TUBE BUNDLE NOT
REMOVABLE

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REMOVABLE BUNDLE OF STHE

Piping
Pulling Area at Plot Plant

Civil
Pulling Load of Bundle

EA-441

EA-217

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Plate Heat Exchanger (GASKETED)

Plate Heat Exchanger (WELDED)

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Battery Limit Scope of Supply

1. Piping
Nozzle flange (Bolt, nut, and gasket by Piping)

Pipe clip welded to equipment
2. Civil
Base plate to foundation or Structure Support. Anchor bolt by??
3. Electrical
Earth Lug

Junction Box Motor (ACHE)

Ladder or Platform
Mounted on Equipment By
Static

Insulation By
Construction
.

2
1
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SUMMARY

1.

2.
3.
4.
5.
6.
7.

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.
Commonly used Heat Exchanger on Industrial Plant : STHE, ACHE, PFHE.
STHE widely used as Heat Exchanger due to its flexibility of design and
operation.
ACHE only aiming for cooling or condensing.
Operation cost of ACHE is lower than STHE.
Pulling area for removable bundle of STHE shall be clearly mentioned on
plot plant.
Etc.

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