PENUKAR KALOR

MAINTENANCE SHELL AND TUBE HEAT EXCHANGER

Disusun :

Damar Agung Deviawan (Paper)

Muhammad Nur Ahmad H (penjawab pertanyaan)
Edwin Reinaldy Sibuea (PPT)
Ginta Alfendo (Presenter)

PROGRAM STUDI TEKNIK MESIN S1

FAKULTAS TEKNIK
UNIVERSITAS RIAU
2019
 MAINTENAN SHELL AND TUBE HEAT EXCHANGER

1. Introduction
Traditionally, when maintenance is performed on shell-and-tube heat exchangers, the
only options considered when tube defects are found are to plug tubes and, when the number
of plugs became too great, replace the heat exchanger. The decision to replace the heat
exchanger was based on a number of factors. These included: the number of tubes plugged, the
number of forced outages due to tube damage (and the cost associated with replacing lost power
and repairing the damaged tubes), the impact that the plugged heat exchanger is having on the
plant (due to lost flow or heat transfer surface area), the rate at which tube plugging is
occurring, the availability of funds to replace the heat exchanger, and the expected life of the
unit (how much longer will the unit operate before retirement).
From a sampling of industry data, tube failures have been shown to cause between 31%
to 87% (depending on the data source) of the events related to feedwater heaters (1). Since so
many of the failures were related to the tubing, the replacement of an entire heat exchanger due
to damage in one area is an expensive as well as a schedule and manpower intensive option.
The typical means for major heat exchanger repair included complete replacement,
rebundling, and returbing, as described below.
 For the replacement option, the heat exchanger shell and tube bunlde are replaced
with a new unit
 For rebundling, the shell is temporarily removed from the ehat exchanger and the
old tube bundle, including, at a minimum, tubes, tubes supports, and tubesheet,
are removed.
 For retubing, either the shell (u-tube design) or tube side acces cover (straight
tubes) is removed from the heat exchanger and the old tubes are removed from
the bundle.
2. Repair vs Replace
There are numerous factors to consider when deciding whether to repair the tubes in a heat
exchanger or to perform a larger repair scope and rebundle or replace the component. The
following factors should be considered when making the repair vs. replace decision.
1) The budget available for repair or replacement needs to be determined. Typically, the
cost of performing a substantial heat exchanger repair (consisting of plug removal, tube
inspection, tube expansion, and sleeving) is less than 10% of the cost of replacing the
 unit. Because of the lower cost, the payback time on the repair option is much shorter
than for replacement.
2) The location and quantity of the tube defects need to be examined to decide if tube
repair is an option. Tube repair may be appropriate if the damage is limited to a certain
area of the tube, which would allow the use of a short repair sleeve.
3) One of the more important items to consider when deciding whether a heat exchanger
can be repaired is the condition of remainder of the heat exchanger.
4) The life exectancy of the power plant needs to be factored into the decision to repair or
replace a heat exchanger.
5) The outage time required to repair a heat exchanger, even when tube and shell side
inspections are performed, is typically much less than for replacement.
6) At nuclear plants, the added cost for the dispoal of radioactively contaiminated heat
exchanger must be taken into account.
7) If the heat exchanger is being replaced to eliminate detrimental materials in the cooling
system then the tube sleeving will not benefical.

3. Maintenance of Heat Exchanger

3.1 Inspection of unit
At regular intervals and a frequently as experience indicates, an examination should be
made of the interior and the exterior of heat exchanger. Neglect in keeping all tubes clean may
result in complete stoppage of flow through some tubes, causing severe thermal strain, leaking
tube joints, or structural damage to other components. When sacrificial anodes are provided,
they should be inspected at regular intervals to determine whether they should be cleaned or
replaced.
3.2 Indication of Fouling
Exchangers subject to fouling or scaling should be cleaned periodically. A light sludge
or scale coating on tubes greatly reduces their efficiency. A marked increase in pressure drop
and/or reduction in performance usually indicates cleaning is necessary. The unit should first
be checked for air or vapor binding to confirm that this is not the cause for reduction in
performance. Because difficulty of cleaning increases rapidly as scale or deposit thickness
increases, intervals between cleaning should not be excessive
3.3 Disassembly for inspection and/or cleaning
Before disassembly, the user must make sure that the unit has been depressurized, vented
and drained, and all hazardous material purged or neutralized.
To inspect the inside of tubes and also make them accessible for cleaning. Use the following
procedures, and reference the chart below.
1. Stationary Head End
 Type A, C, D, & N – remove cover plate only
 Type B – remove entire bonnet
2. Rear Head End
 Type L, N, & P – Remove cover plate only
 Type M – Remove entire bonnet
 Type S or T – Remove shell cover and floating head cover
 Type W – Remove channel cover plate or entire bonnet

Figure 1 Type tube ( JFD tube & Coil products, inc.)

4. Repair Option
4.1 Plug
The initial option, after the problem tubes have been located (either through non-
destructive examinations, such as eddy current testing, visual inspections, or leak tests) is
to plug the tube. Depending on the type of service and operating pressures of the heat
exchanger, various types of plugs are employed
4.2 Sleeving
An alternate approach to retubing, rebundling, or replacement of a heat exchanger is
to install sleeves over the defective portions of the tubes. The sleeve consists of a smaller
diameter piece of tubing that is inserted into the parent tube and positioned over the tube
defects.

Figure 2 Heat Exchanger Sleeve Design

4.3 Tube expansion

In addition to sleeving, it is possible to expand the tube to improve the heat exchanger
performance. These tube repairs can minimize further tube damage and maximize the
useful life of the heat exchanger.

5. Replaced Option
5.1 Retubing
The tubes can be replaced, if the unit has : straigh tubes, good access, and the
remaining components of the heat exchanger
 Figure 3 Codenser Retubing

5.2 Rebundling
Some heat exchangers are designed to be rebundled rather than replaced. For these
units the entire tube bundle, including tubes, tubesheet, and tube supports are replaced, as
shown in Figure 4

Figure 4 heat exchanger Rebundling

5.3 Complete Replacement (New Unit)

A third and typically widely used option is to replace the entire heat
exchanger, as shown in Fig.5 . Full replacement allows alternate tube materials,
changes in heat transfer area, and structural changes to be employed, including
added clearances in areas where erosion or other problems may be occurring, to
ensure that the current heat exchanger problems do not re-occur in the future.
Figure 5 Heat exchanger Replacement
 DAFTAR ISI

Ali A. Rabah, Heat exchangers: design, Operation, maintenance and enchantment. University
of Khartoum

JFD Tube And Coil Products. Installation, Operation, & Maintenance Instructions For JFD
Shell & Tube Heat Exchangers.

Levent Ali. 2016. ABOUT THE MAINTENANCE OF THE HEAT FLOW EXCHANGERS
FROM ENERGETICALLY NAVAL SYSTEMS. Military Technical Academy

Thermex LTD. Shell And Tube Heat Exchangers: Installation, Operation and Maintenance
Manual