INSPECTION OF DOUBLE TUBESHEET HEAT EXCHANGERS

AT CONFERENCE HALL ON 2ND DEC.2005

Presented by Mr. Prasad Pathak

For the benefit of business and people

1 Information Double T/S H.E.

2 Thumb rules
3 Introduction
CONTENTS

4 Tube Sheet Details 5 Tube To Tube Sheet Joint 6 Tube Sheet To Tube Sheet Joint 7 Requirement Of Mock Up 8 Mock Up Testing
6.1 DIM. Report of Mock Up 6.2 Expn. Record of Mock Up 6.3 Pull Out Record of Mock Up

9 Problems Incurred 10 Customers Concurrence 11 Conclusion

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INFORMATION ON DOUBLE TUBE SHEET HEAT EXCHANGERS

HEAT EXCHANGERS

DOUBLE TUBESHEET EXCHANGERS

INTEGRAL DOUBLE TUBESHEETS

The tube sheet are connected in a manner which:

Distributes axial load. Distributes radial thermal expansion loads . The interconnecting element is capable of preventing individual radial growth of tubesheet.

ASSUMPTIONS:

Element is rigid enough to mutually transfer all thermal and mech. radial loads between t/sheets. Tubes are rigid enough to mutually transfer all mechanical and thermal axial loads between the tubesheets
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HEAT EXCHANGERS

DOUBLE TUBESHEET EXCHANGERS

CONNECTED DOUBLE TUBESHEETS

The tube sheet are connected in a manner which :

Distributes axial load between tubesheets by means of cylinder. The effect of differential radial growth between t/s is a major factor in tube stresses and spacing between t/sheets

ASSUMPTION:

Interconnecting cylinder and tubes are rigid enough to mutually transfer all mech. and thermal axial loads between the tubesheets.
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HEAT EXCHANGERS

DOUBLE TUBESHEET EXCHANGERS

SEPARATE DOUBLE TUBESHEET

The tube sheets are connected only by inter connecting tubes. The effect of differential radial growth between t/s is a major factor in tube stresses and spacing between t/sheets

ASSUMPTIONS:

No loads are transferred between the tubesheets.

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THUMB RULES IN STREAM
ALLOCATIONS

HEAT EXCHANGERS

THUMB RULES IN STREAM ALLOCATION

PRACTICAL GUIDELINES FOR OPTIMUM DESIGN FLUID STREAM ALLOCATIONS:

The higher pressure fluid normally flows through the tube side. With smaller diameter and nominal wall thk. the tubes are better able to accept high pressures. Thus larger diameter is avoided for larger pressures. Generally corrosive fluids are in the tubeside. This is much less expensive to use the special alloys designed to resist corrosion for tubes than for shell. Flow of higher fouling fluids through the tubes are easier to clean using common mech. methods than the shell .

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HEAT EXCHANGERS

THUMB RULES IN STREAM ALLOCATION CONTD

It is best to place fluids requiring low pressure drops in the shell circuit since flexible combinations & configurations- affecting tube pitch, baffle use and spacing, and multiple nozzles etc can be used when laying out the shell circuit.

The fluid with lower heat transfer coeff. normally goes in the shell circuit with this setup, low-fin tubing, which will increase available surface area,can be used to offset the low heat transfer.

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INTRODUCTION

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HEAT EXCHANGERS

INTRODUCTION

Usually we come across inspection of straight tube and U tube Heat Exchangers with single Tube sheet at either ends or single Tube sheet at one end(U tube HE). TEMA provides option for using Double Tube sheet HE to get a better contamination-proof joint.( ref.TEMA RCB pg.55-62) Such design of exchangers are popular in Pharma industries where intermixing of shell side and tube side fluid are totally to be avoided for process reasons. It would be worthwhile attempting to describe how the double tube sheet avoids intermixing. Pl. refer the figure.

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HEAT EXCHANGERS

INTRODUCTION

HEAT EXHCHANGER DETAILS

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HEAT EXCHANGERS

INTRODUCTION

TYPICAL JOINT DOUBLE TUBESHEET

Shell Inner T/S Outer T/S

Channel Shell Tubes

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HEAT EXCHANGERS

INTRODUCTION

GENERAL DETAILS ABOUT THE JOB INCLUDING OVERALL DIMNS. :

HCL Hydrogenation Heater for Reliance Industries Limited ,Hazira PROCESS FLUID:- SHELL SIDE - HCL / TUBE SIDE - STEAM* U Tube Double Tube sheet HE.

DIMENSIONS :

Overall Length 6931 mm. SHELL ID 440 mm x 12 Thk, TUBESHEET 476 OD

MATERIAL :

Shell / Dish end SA 516 Gr 70 Tube sheet SA 350 Gr LF2 46mm & 71mm ThK U Tubes SA 334 Gr 6 19.05 OD x 2.77 mm thk

* SINCE THE PROCESS FLUID WAS STEAM, CUSTOMER CONFIRMATION OF IBR WAS SOUGHT.

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TUBE SHEET DETAILS

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HEAT EXCHANGERS

TUBE SHEET DETAILS

TubeSheet - SA 350 Gr LF2. X 476 dia.

First T/s 46mm( inner) & second 71 mm ( outer). Each T/s having two grooves of 3mm width and 0.4mm depth. 148 No of holes each of Dia. 19.25mm on 25.4mm traingular pitch.

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TUBE TO TUBE SHEET JOINT

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HEAT EXCHANGERS

TUBE TO TUBE SHEET JOINT

Tube SA 334 Gr 6 Size 19.05mmx 2.77 mm Thk Fully expanded joint. 8 to 10% expansion % Thinning check and air test after expansion.

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TUBE SHEET TO TUBE SHEET
JOINT

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HEAT EXCHANGERS

TUBE SHEET TO TUBE SHEET JOINT

Full penetration joint with 25 mm gap in between the Tube sheets. NDT as per drawing MPI NDT suggested PT and UT in addition to MPI.

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REQUIREMENT OF MOCK UP

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HEAT EXCHANGERS

REQUIREMENT OF MOCK UP

WHY THE MOCK UP WAS REQUIRED TO BE DONE: ( TEMA DOESNT CALL FOR SUCH TESTS FOR U-TUBE EXCHANGERS)

To establish expansion parameters. To check % thinning after expansion To check axial load (pull out ) of tubes after expansion.

To check proper flow of tube material in the T/s grooves after expansion.
To freeze the sequence of the expansion of the T/s to Tube joint.

SINCE TUBE SHEET ASSLY HAD DOUBLE EXPN. PORTION, IT WAS ESSENTIAL TO DEMONSTRATE THE EXPANSION ACHIEVED IN THE INNER TUBESHEET.

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MOCK UP TESTING

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HEAT EXCHANGERS

MOCK UP TESTING

DESCRIPTION OF THE MOCKUP:

Tube sheets with same configuration as required in job. 17 No of holes used. Pull out test carried out on Hole nos. 4,9&14 ,surrounded by at least two rows.

Expansion in two stages.

% expansion checked in both Tube sheets with bore gauge.

ADDITIONAL TESTS DONE ON THE MOCKUP:

After satisfactory expansion, the joint with annular space was seal welded first and then subjected to pneumatic test at 2.0 kg/cm2(g). pressure followed by hydro test at 33.0 kg/cm2(g) and the results were leak tight.

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8.1

HEAT EXCHANGERS

DIM. REPORT OF MOCK UP

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8.2

HEAT EXCHANGERS

EXPN. RECORD OF MOCK UP

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8.3

HEAT EXCHANGERS

PULL OUT RECORD OF MOCK UP

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8.4

HEAT EXCHANGERS

PULL OUT RECORD OF MOCK UP CONTD..

The pull out loads were found to be satisfactory when the tests were done :-

1. 2.

Required load - 56 kn actual 80 kn Macro test was conducted after sectioning to confirm the proper flow of tube material in the grooves after expansion, the flow of material was satisfactory.

3.

Hardness test were done on the inner expanded & unexpanded surface of the tube and was with in 187 bhn.

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PROBLEMS INCURRED

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9.1

HEAT EXCHANGERS

PROBLEMS INCURRED

REQUIREMENT OF EXTRA LONG DIAL BORE GAGE FOR THE INNER TUBESHEET:

In mock up stage , both ends of the tube sheets were accessible and hence it was easy to check % expansion in both the tube sheets separately. In actual job, only one end was accessible. So it required a long bore gauge to check the expansion. Since the fabricator was not having the long bore gauge,expansion of the outer T/s was checked and reported. The same was referred to client for concurrence and was accepted by them based on satisfactory mock up results.

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9.1

HEAT EXCHANGERS

PROBLEMS INCURRED CONTD..

NDT SPECIFIED FOR THE EQPT WAS 100% RADIOGRAPHY :

BV insisted the above requirement for the T/S TO T/Sheet weld joint Due to the joint geometry, radiography could not be realised. UT was the next suggested alternative. Again due to joint configuration /lesser width of joint & limitation of scanning area only a small portion could be examined leaving out the critical root penetration. To counter this, special care for the root pass was undertaken by keeping 3 visible ports for examining the root penetration visually. The root penetration was found satisfactory. As per approved QAP only MP examination was specified for this joint and hence accepted on this basis.

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9.2

HEAT EXCHANGERS

BV INSPECTION REPORT

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9.2

BV INSPECTION REPORT
HEAT EXCHANGERS
CONTD..

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CUSTOMERS CONCURRENCE

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HEAT EXCHANGERS

CUSTOMERS CONCURRENCE

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CONCLUSION

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HEAT EXCHANGERS

CONCLUSION

TEMA does not give too much details about such type of Double T/s HE.

Maximum care was taken to do all possible testing and checks to establish fool proof joint.
Still a better version of checks and testing may be possible. Any additional information and experience on this topic is welcome.

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