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Heat Exchangers Sept 19

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Anandan Gunasekaran
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11 views

Heat Exchangers Sept 19

Uploaded by

Anandan Gunasekaran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Management Level

Engineering Knowledge

Heat Exchangers

Click to add text


CLASSIFICATION: 2 - Internal or Non-Confidential
Radiation Convection Conduction

CLASSIFICATION: 2 - Internal or Non-Confidential


Overall Q = UθA
U = coefficient of heat transfer (fluids, speed/mass flow
rate, turbulence/streamline, heat exchanger materials)
θ = logarithmic mean temp difference
A = area (heat exchanger surface)

Convection only Q =
hcA∆t hc = heat transfer
coefficient Area = area of
surface
∆t = temp diff (surface & fluid)

Conduction only Q = kA∆t


x
K = thermal conductivity of material (Cu=385, Al=200,
Fe=64W/mK) A = surface area

∆t = temp diff
x = material thickness
CLASSIFICATION: 2 - Internal or Non-Confidential
(Contra)

Hot

Cold

Adv: Outlet never too Adv: Uniform diff = ↑eff


hot (e.g. FO htr) + ↓distortion = (e.g. econr)
Disadv: ↑diff @ inlet Disadv: Outlet temp may >
= ↑distortion
+ ↓eff
CLASSIFICATION: 2 - Internal or Non-Confidential
to
t1
θo

θi

Good heat transfer

CLASSIFICATION: 2 - Internal or Non-Confidential


Mix of all = adv of all
Baffles = long residence time = better
for poor heat transfer materials e.g. LO

CLASSIFICATION: 2 - Internal or Non-Confidential


Boundary layer of
poor heat exchange (Lamina)
CLASSIFICATION: 2 - Internal or Non-Confidential
Performance problems
• Air locking - insulator (leaking seals, high
sea suction, cavitation)

• Fouling - insulator (scale, sediment,


organic slime, mussels, plastic bags)

CLASSIFICATION: 2 - Internal or Non-Confidential


Fouling

CLASSIFICATION: 2 - Internal or Non-Confidential


• By-passing - joint/division plate hole

• Impingement (erosion + corrosion) – erosion of


protective film by high velocity followed by
corrosion of exposed surface

CLASSIFICATION: 2 - Internal or Non-Confidential


• De-zincification – zinc removed from brass (=
weak copper)

• Graphitisation – iron removal from steel (= soft


graphite)

• Anaerobic attack – H2S (= corrosion)

• Deposit attack – sand, mud, shellfish (= low


oxygen diff aeration corrosion cell)

• Incompatible fittings- galvanic cell (= corrosion)

CLASSIFICATION: 2 - Internal or Non-Confidential


Typical Shell and Tube Type construction
Lub Oil
Outlet Water
Water Lub Oil
Inlet Tube Box
Box Nest
Baffles

Sea
Water
Outlet

Sea
Water
Tube
Inlet
Plate
Shell
CLASSIFICATION: 2 - Internal or Non-Confidential
Single and multi-pass

(two pass)

CLASSIFICATION: 2 - Internal or Non-Confidential


Tube Plates

Fins
Capped /
sealed tube

Steam Su ppl

Tube Plate Condensate


Return

CLASSIFICATION: 2 - Internal or Non-Confidential


How is expansion catered for?

U tubes

CLASSIFICATION: 2 - Internal or Non-Confidential


Sliding tube plate

CLASSIFICATION: 2 - Internal or Non-Confidential


Expansion joints in shell

CLASSIFICATION: 2 - Internal or Non-Confidential


LEAK DETECTION

VACUUM TESTING (1) - Thermometer pocket + vacuum


pump, cling film is pulled in or foam is pulled in i.e. “Hole”
appears.

VACUUM TESTING (2) - Tubes plugged with rubber bung


one end, vacuum generator + gauge other end, if the vacuum
deteriorates.

CLASSIFICATION: 2 - Internal or Non-Confidential


PRESSURE TESTING - The shell side is filled with water,
often with a fluorescent dye added. A pressure is maintained
on the shell side by connection to a domestic water supply.
With the tubes blown through and dried with compressed air,
any subsequent water egress from the tubes indicates the
presence of a leak.

ULTRASONIC – sound source in shell, probe in tube


‘hears’ sound

REFRIGERANT – probe ‘smells’ gas or halide torch


(flame changes colour)

CLASSIFICATION: 2 - Internal or Non-Confidential


Tube Repair

1. PLUGGING
2. BY SOLDERING/SWEATING or BRAZING
3. BY EXPANDING OR ROLLING
4. BY USE OF FERRULES AND GROMMETS

CLASSIFICATION: 2 - Internal or Non-Confidential


EXPANDING OR ROLLING

CLASSIFICATION: 2 - Internal or Non-Confidential


FERRULES AND GROMMETS
Originally used for condensers, due to their ease of
removal and fitting. Easily done by ships crew with
only a ferrule spanner. Modern steamships can have
Titanium tubes rolled and brazed in position.

https://boilermakers.org/news/jobs/70_million_dollar_project_brings_upgrades_to_Colstrip_plant
CLASSIFICATION: 2 - Internal or Non-Confidential
Instrumentation

• Liquid ‘A’ Temp diff


Press diff
• Liquid ‘B’ Temp diff
Press diff

CLASSIFICATION: 2 - Internal or Non-Confidential


COOLER PROTECTION
Internal coating - bitumen

ANODES

The materials for S.W. coolers are selected for their


corrosion resistance, but additional protection is
normally considered necessary.

CLASSIFICATION: 2 - Internal or Non-Confidential


Ferrous (soft iron) anodes
These are used to protect cupro-nickel pipework
which is commonly found on many vessels. By
producing ferrous ions, the ‘soft iron’ anode helps to
maintain a protective oxide layer on the internal
surfaces of pipes to suppress corrosion. The anode
is shown with a cofferdam arrangement.

CLASSIFICATION: 2 - Internal or Non-Confidential


FERROUS SULPHATE INJECTION

Ferrous ions may be added to the system by dosing with ferrous-


sulphate, a liquid or powder chemical which is diluted to the
specified concentration (typically 1 p.p.m.) and fed into the
system by metering pump or gravity, over a specified period, say
1 hour per 24.

Electrical continuity in the sea-water circulating pipework is


important where sacrificial anodes are installed. Bonding straps
are fitted across flanges and cooler sections where there are
rubber joints and 'O' rings, which otherwise insulate the various
parts of the system.

CLASSIFICATION: 2 - Internal or Non-Confidential


Aluminium and copper anodes

Anti-bio fouling process through the production of


aluminium hydroxides and/or copper ions. They also
produce a cupro-aluminium film which acts as an anti-
corrosive layer on the internal surfaces of pipes.

CLASSIFICATION: 2 - Internal or Non-Confidential


CORROSERT

Turbulence (cavitation)
Protection

CLASSIFICATION: 2 - Internal or Non-Confidential


ELECTRO-CHLORINATION
To protect the cooler from weed, organic slime, mussels etc.,
chlorine may be added to the sea water system by
electrolyzing sea water
NaCl + H2O + energy = NaOCl + H2

CLASSIFICATION: 2 - Internal or Non-Confidential


Box or keel cooling configurations

No pumps, strainers etc

CLASSIFICATION: 2 - Internal or Non-Confidential


Plate Type Heat
Exchangers Stainless steel
Titanium

Nitrile rubber

CLASSIFICATION: 2 - Internal or Non-Confidential


Corrugations

Turbulence =
↑ heat exchange
– Smaller
↓ fouling
– Less maintenance

Strength =
↓ thickness
- Better heat transfer

(3x better than shell + tube)

CLASSIFICATION: 2 - Internal or Non-Confidential


Plate Type

Easily/Rapidly opened-
• Cleaning No extra
• Replacement Space
• Adding/removing
CLASSIFICATION: 2 - Internal or Non-Confidential
Cleaning plates

CLASSIFICATION: 2 - Internal or Non-Confidential


Thermal Length (θ)

Smaller angle Larger angle


Lower press drop Higher press drop
Less heat transfer More heat transfer
Lower flow resistance Higher flow resistance

CLASSIFICATION: 2 - Internal or Non-Confidential


ADVANTAGES:-
• Plate Coolers are smaller and lighter than a tube
cooler for the same efficiency.
• Easy to dismantle and replace damaged plates or
fit extra plates (in pairs) to increase capacity.
• Simple to clean. Turbulent flow helps reduce deposits
on plates, which could interfere with heat transfer. No
extra space needed for dismantling.

DIS-ADVANTAGES:-
• Joints and plates are expensive.
• Leaks are difficult to locate because the plates cannot
be pressurised and tested as easily as tube coolers.
• Joints can deteriorate and can be difficult to remove and
bond new joints to the plates.
• Over tightening of the clamping bolts can cause
damage to the plates.

CLASSIFICATION: 2 - Internal or Non-Confidential


Charge air cooler
Heat transfer better with cross-flow
Fins increase surface area

CLASSIFICATION: 2 - Internal or Non-Confidential


Central cooling system

↓ SW =
↓ Corrosion
↓ Expensive materials
80ºC

↓ LO cooler leak
pollution
↓ Ships side v/v’s
↓ Failure risk
↓ Strainers
↓ Maintenance
↓ Survey

CLASSIFICATION: 2 - Internal or Non-Confidential


CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
CLASSIFICATION: 2 - Internal or Non-Confidential
Capped /
sealed tube

Tube Plate Condens


Return

CLASSIFICATION: 2 - Internal or Non-Confidential

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