Baffles are provided in the shell to direct the fluid flow and support the tubes. This tube type lubricating oil heat exchanger adopts the logarithmic mean temperature. Plate and shell heat exchangers have become very popular over the last decades thanks to their high thermal efficiency, compact size and ability to withstand high pressures. Because of the need to perform a dynamic analysis and the potential for atmospheric discharge, many companies make the decision to take advantage of the second method that api 521 allows to mitigate the tube rupture scenario.
Failure analysis of heat exchanger tubes springerlink. Failure analysis of heat exchanger tubes in the indirect aircooled rotary shell 297 operates above capacity limits will cause deterioration to the tubes. Failure analysis of a shell and tube oil cooler request pdf. The ends of the tubes are fitted into tube sheets, which separate the shellside. Ppt on failure analysis of shell and tube heat exchangers.
Shellandtube heat exchangers are one of the most important and commonly used process equipment items in the chemical process industries cpi. In systems that involve steam heating, the cool down or condensing of residual steam on the shell side after the steam control valve closes will continue to heat water or other such fluids on the tube side. The floating head type heat exchanger is the most versatile type of heat exchanger. Plant oa operating agent op observed population npp nuclear power plant phwr heavy water moderated, pressure tube reactor pra probabilistic risk assessment psa probabilistic safety assessment. Two important problems in heat exchanger analysis are i rating existing heat exchangers and ii sizing heat exchangers for a particular application. A plan for increasing heat exchanger performance for shell and tube.
Failure analysis of shell and tube heat exchangers raj kulsange mis no121524006 under guidance of. Plate type heat exchanger this is constructed by a series of corrugated parallel plates held firmly together between frames. Analysis of chemical plant heat exchanger explosion. Failure analysis of stainless steel heat exchanger tubes. The vertical fixed shell tube heat exchanger failed to work in one chemical plant, and the leakage of the heat exchanger tubes were found after the examination.
The optimum thermal design of a shell and tube heat exchanger involves the consideration of many interacting design parameters which can be summarized as follows. Process fluid assignments to shell side or tube side. Failure analysis was carried out on a tubetotubesheet welded joint of a shelltube heat exchanger to confirm its failure mechanism. The study of failure analysis of shell and tube heat exchangers will help to understand methods to analyze various types of failure in shell and tube heat exchangers.
Heat exchanger is the equipment which is used college of engineering pune. Jul 08, 2016 ppt on failure analysis of shell and tube heat exchangers 1. Failure analysis of heat exchanger tubes request pdf. Failure analysis of shell and tube heat exchanger free download as word doc. The failure analysis of shell and tube heat exchanger at hocl is done. The optimum thermal design of a shell and tube heat exchanger involves the consideration of many interacting design parameters which can be summarised as follows.
Typically there are 4 types of failures in heat exchanger. One of these tubes was analyzed in this examination. Thermostructural fatigue and lifetime analysis of a heat. As a critical component within the process plant environment keeping your heat exchangers maintained, clean and in good working order will help prevent against unintentional shutdowns and costly unplanned maintenance. Failure analysis of tubetotubesheet welded joints in a. Failure analysis of heat exchanger tubes sciencedirect. In this study, the design of a shell andtube counterflow heat exchanger in autocad software is first considered, and the system is. Tube side medium in this heat exchanger was sour gas coming from high pressure separators and shell side. The heat exchanger was of the bayonet type with boiler water inside the tubes and secondary reformer outlet process gas at the shell side. Failure analysis of tube and shell heat exchanger ijraset. Fatigue started at initial defects of the welded joint was con. Failure analysis of cracks occured on ss304l tubes of. A heat exchanger is a heat management system that uses fluids to transfer heat from one medium to the other. In this white paper, we show that fatigue problems can be.
Failure analysis and optimisation of tube water cooler of hydropower plant bambang teguh p. Any corrosion already present is accelerated as erosion removes the tube s protective films, exposing fresh metal to further attack. Failure analysis of authentic stainless steel tubes in a. The objectives of the investigation are to identify the failure mechanism and possible contributing factors and suggest corrective actions to prevent reoccurrence of similar failure. Guidelines for the safe design and operation of shell and. The heat exchanger reliability study is vital in all related industries as inappropriate maintenance and operation of the heat exchanger will lead to major process safety events pse and loss of production. Background a shelltube heat exchanger was found failed when it was used about 30 days after assembling. He heat exchanger ht general failure mode failure of heat transfer. Dozens of leak points were found near the tubetotubesheet welded joints of the shelltube heat exchanger. Common causes of heat exchanger failure november 2, 2018.
Vibrations and fatigue are the examples of most dangerous causes that can cause failure. Design and analysis of a heat exchanger with helical baffles. The us chemical safety board investigates industrial accidents in the chemical industry, providing analysis that can be used to promote and. A failure analysis of air heat exchanger based on modal. Principles of finned tube heat exchanger design for enhanced heat transfer 2nd edition by dipl. When the problem is to determine the inlet and outlet temperatures for a particular heat exchanger, the analysis is. Primary waste heat exchanger tubes of material astm a2 grade t11 failed after operation of only three and a half months. A shell and tube heat exchanger reliability was done in this study using past history data from a carbon black manufacturing plant. Feb 21, 2017 analysis of chemical plant heat exchanger explosion. This is one of the common type of heat exchanger, a combination of shell and tube as shown in the figure, this shell and tube exchanger consists of a number of tubes mounted inside a cylindrical shell in which tubes runs parallel to shell.
A shell and tube heat exchanger had failed its four tubes after just over a year in service. Temperature analysis of shell and tube heat exchanger. The shell and tube heat exchanger is equipment largely used at chemical industries. The present work investigated the effect of shell diameter and tube length on heat transfer coefficient and pressure drop for shell side with both triangular and. Jul 08, 2016 report on failure analysis of shell and tube heat exchangers 1. Shell and tube style heat exchangers are the most common kind of heat exchangers used in industries. Pdf failure analysis of tubetotubesheet welded joints. In this paper failure analysis of ss304l tubes in a shell and tube heat exchanger within one of the gas refineries in south pars gas complex spgc has been investigated. The mechanical design of a shell and tube heat exchanger provides information on items such as shell thickness, flange thickness, etc. Heat exchanger tube rupture analysis the equity engineering. Failure analysis was carried out on a tube totubesheet welded joint of a shell tube heat exchanger to confirm its failure mechanism.
Paper open access related content reliability analysis on a. Performance analysis of shell and tube heat exchanger. Shell and tube heat exchangers are having special importance in boilers,oil coolers, condensers, preheaters. In present day shell and tube heat exchanger are the most common type heat. Failure analysis of cracks occured on ss304l tubes of shell. If any corrosion is already present on the exchanger, the erosion is accelerated, exposing. The us chemical safety board investigates industrial accidents in the chemical industry, providing analysis that. Any corrosion already present is accelerated as erosion removes the tubes protective films, exposing fresh metal to further attack. From the analysis, various reasons behind the failure of this heat exchanger are found which mainly includes the lack of availability of heat transfer area and higher requirement of heat transfer area. Today, the use of shell and tube heat exchangers has become widespread and they are used in various industries under very diverse operating conditions. A heat exchanger can be designed by the lmtd when inlet and out let conditions are specified. Jun 05, 2006 now, with eddy current analysis, all manner of tube defects are detectable in heat exchangers with similar accuracy as the mills experience when testing new tubes for minute flaws. The collected evidence suggests that the failure of the tube totubesheet welded joint was induced by fatigue.
These are calculated using a pressure vessel design code such as the boiler and pressure vessel code from asme american society of mechanical engineers and the british master pressure vessel standard, bs 5500. Troubleshooting shellandtube heat exchangers use these techniques and guidelines to ensure more reliable heat transfer d. In thermal systems, heat exchangers are used to control the operating temperature of the working fluids. The main reason for tube failure due to flow induced vibration is increased size of sthe. The collected evidence suggests that that failure of the tube. Satynarayana rao2 research scholar, osmania university1, retd. According to the heat exchanger design manual, when the ratio of the. The collected evidence suggests that the failure of the tubetotubesheet welded joint was induced by fatigue. Detailed design has been improved and optimized over the years, even on minor details that can affect reliability and maintenance. Pdf design optimization of shell and tube heat exchanger. The temperature of the process gases was 960 c and the heat exchanger was producing steam at a temperature of 306 c and a pressure of 1500 psig. Nov 11, 2014 this paper presents a failure analysis performed to investigate the leak of heat exchanger tubes. There are various causes by which heat exchanger may fail.
Specific operating conditions make it possible to consider and simulate the operating terms and failure conditions of these converters. Collection and analysis of commoncause failures of heat. Shell and tube cooler shell and tube heat exchanger consists of a bundle of tubes enclosed in a cylindrical shell. Failure analysis of stainless steel heat exchanger tubes in a. As its name implies, this type of heat exchanger consists of a shell a large tube surrounding a bundle of tubes. Professor, cmrit2 abstract heat exchangers are used extensively in engineering applications. Design optimization of shell and tube heat exchanger by vibration analysis.
In this type of heat exchanger one tube sheet is fixed relative to the shell, while. Gulley, gulley computer associates, tulsa, oklahoma. Most metal erosion problems occur inside the tubes. Ppt on failure analysis of shell and tube heat exchangers 1. Failure analysis of shell and tube heat exchanger corrosion. Setting shell side and tube side pressure drop design limits. Pdf enhancement of heat transfer through shell and tube exchangers stills taking high attention by researchers. College of engineering pune introduction of heat exchangers 3. Shell and tube heat exchangers are one of the most commonly used type of heat exchangers in the industry for heat exchange purpose. Mitigation method 2 perform detailed analysis on heat exchanger to designate the tube rupture scenario as noncredible. Thorough failure analysis showed that sulfur was obviously detected on both tube side surfaces od and id. The failure of shell and tube heat exchangers is being extensively experienced by the chemical process industries. This heat exchanger is used to transfer heat from steam on the shell side to slurry on the tube side. Failure analysis and optimisation of tube water cooler of.
Abstractthis paper deals with the failure analysis of air heat exchanger. This failure can create a loss of production for long time duration. To reduce the cost of heat exchanger retubing, we also offer eddy current tube analysis. The transfer of heat takes place through the surface of the tubes. To commission a new design requires regulatory approval. A resulting heat load with nowhere to go will cause thermal expansion, creating pressure well in excess of the tube, tube sheet, cast head. Karl ponweiser institute for thermodynamics and energy conversion vienna university of technology vienna, austria published by wseas press. Each failure very high cost to hocl in terms of production loss due to down time for maintence and due to the loss of therminol liquid to the process. Pdhonline course m371 2 pdh shell and tube heat exchangers. The failed, used and new heat exchanger tubes were subjected to stereooptical microscopy, chemical analysis and hardness testing. An eddy current test will identify which tubes need to be replaced and which can remain in service. Abstract failure analysis was carried out on a tubetotubesheet welded joint of a shelltube heat exchanger to confirm its failure mechanism.
Heat exchanger ppt free download as powerpoint presentation. If you are working on a project during either the basic or the detailed engineering phase, there is a good chance that you will need to specify one or more shell andtube exchangers and perhaps many. Click here to get a preliminary idea about shell and tube heat exchangers. The inner row of external bolts is used to increase the seating load between the tubesheet and shell gasket heta the event of relaxation of the inner bolts. Under the morphology analysis, the fracture surface exhibit obvious fatigue crack propagation traces. The resultant tube failure can occur in a relatively.
Design optimization of shell and tube heat exchanger by vibration analysis shravan h. The tubes in a heat exchanger are tested by insertion of a probe the full tube length. Ubarhande2 1department of mechanical engineering, modern education societys college of engineering, pune india. The tube material was made of sa 249 tp 304l, a standard specification for welded austenitic stainless steel tubes. This paper presents a failure analysis performed to investigate the leak of heat exchanger tubes. In this work, shell and tube heat exchanger performance analysis is performed using cfd tools under industrycollected boundary conditions. In hocl, a shell and tube heat exchanger is used in the production line of phenol. Collection and analysis of common cause failures of heat exc hangers april 20. Pdf performance analysis of shell and tube heat exchanger. Impulses are fed back to a console, which shows the tube s condition. Fiorentin, et al noise and vibration analysis of a heat exchanger. Abstract failure analysis was carried out on a tube totubesheet welded joint of a shell tube heat exchanger to confirm its failure mechanism.
To determine the cause of the failure, analysis and. Analysis of chemical plant heat exchanger explosion youtube. However, many companies have discovered that this type of heat exchanger is sensitive to metal fatigue. Heat exchanger is the equipment which is used to reduce temperature of one process fluid, which is desired to cool, by transferring heat to another fluid which is desired to heat with or without intermixing the fluid or changing the physical state of the fluid.
Accelerometer and microphone positions in the heat exchanger. Pressure vessels are strictly regulated in north america and elsewhere in the world. In addition, we will examine various aspects of heat exchanger design and analysis. Design optimization of shell and tube heat exchanger by. Principles of finnedtube heat exchanger design for enhanced heat transfer 2nd edition by. Scribd is the worlds largest social reading and publishing site. Design and analysis of a heat exchanger with helical.
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