Today, the use of shell and tube heat exchangers has become widespread and they are used in various industries under very diverse operating conditions. Gulley, gulley computer associates, tulsa, oklahoma. A resulting heat load with nowhere to go will cause thermal expansion, creating pressure well in excess of the tube, tube sheet, cast head. Abstract failure analysis was carried out on a tube totubesheet welded joint of a shell tube heat exchanger to confirm its failure mechanism. Heat exchanger is the equipment which is used college of engineering pune. College of engineering pune introduction of heat exchangers 3. Ppt on failure analysis of shell and tube heat exchangers.
Heat exchanger tube rupture analysis the equity engineering. One of these tubes was analyzed in this examination. The resultant tube failure can occur in a relatively. Failure analysis of cracks occured on ss304l tubes of. Typically there are 4 types of failures in heat exchanger. The ends of the tubes are fitted into tube sheets, which separate the shell side and tube side fluids. Failure analysis was carried out on a tubetotubesheet welded joint of a shelltube heat exchanger to confirm its failure mechanism. Jul 08, 2016 report on failure analysis of shell and tube heat exchangers 1. Any corrosion already present is accelerated as erosion removes the tubes protective films, exposing fresh metal to further attack.
Pdf design optimization of shell and tube heat exchanger. Jul 08, 2016 ppt on failure analysis of shell and tube heat exchangers 1. Professor, cmrit2 abstract heat exchangers are used extensively in engineering applications. Abstract failure analysis was carried out on a tubetotubesheet welded joint of a shelltube heat exchanger to confirm its failure mechanism. 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.
Mitigation method 2 perform detailed analysis on heat exchanger to designate the tube rupture scenario as noncredible. Any corrosion already present is accelerated as erosion removes the tube s protective films, exposing fresh metal to further attack. In this study, the design of a shell andtube counterflow heat exchanger in autocad software is first considered, and the system is. Setting shell side and tube side pressure drop design limits. Failure analysis and optimisation of tube water cooler of hydropower plant bambang teguh p. 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. Detailed design has been improved and optimized over the years, even on minor details that can affect reliability and maintenance. The collected evidence suggests that that failure of the tube. 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. A plan for increasing heat exchanger performance for shell and tube. To reduce the cost of heat exchanger retubing, we also offer eddy current tube analysis. 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.
The failed, used and new heat exchanger tubes were subjected to stereooptical microscopy, chemical analysis and hardness testing. Temperature analysis of shell and tube heat exchanger. Primary waste heat exchanger tubes of material astm a2 grade t11 failed after operation of only three and a half months. 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. Thermostructural fatigue and lifetime analysis of a heat. Heat exchanger failure analysis of heat exchanger page. Failure analysis of authentic stainless steel tubes in a. 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. A shell and tube heat exchanger reliability was done in this study using past history data from a carbon black manufacturing plant. 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. 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.
Impulses are fed back to a console, which shows the tube s condition. Performance analysis of shell and tube heat exchanger. Background a shelltube heat exchanger was found failed when it was used about 30 days after assembling. Nov 11, 2014 this paper presents a failure analysis performed to investigate the leak of heat exchanger tubes. Vibrations and fatigue are the examples of most dangerous causes that can cause failure. Collection and analysis of common cause failures of heat exc hangers april 20. A heat exchanger is a heat management system that uses fluids to transfer heat from one medium to the other. 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. He heat exchanger ht general failure mode failure of heat transfer. When the problem is to determine the inlet and outlet temperatures for a particular heat exchanger, the analysis is. Failure analysis of a shell and tube oil cooler request pdf. An eddy current test will identify which tubes need to be replaced and which can remain in service.
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. Troubleshooting shellandtube heat exchangers use these techniques and guidelines to ensure more reliable heat transfer d. The us chemical safety board investigates industrial accidents in the chemical industry, providing analysis that. The failure of shell and tube heat exchangers is being extensively experienced by the chemical process industries. A shell and tube heat exchanger had failed its four tubes after just over a year in service. The collected evidence suggests that the failure of the tubetotubesheet welded joint was induced by fatigue. Karl ponweiser institute for thermodynamics and energy conversion vienna university of technology vienna, austria published by wseas press. 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. Design and analysis of a heat exchanger with helical. Failure analysis of heat exchanger tubes sciencedirect. The floating head type heat exchanger is the most versatile type of heat exchanger. Pressure vessels are strictly regulated in north america and elsewhere in the world. The ends of the tubes are fitted into tube sheets, which separate the shellside.
Design and analysis of a heat exchanger with helical baffles by using cfd basawaraj s. This failure can create a loss of production for long time duration. Pdf failure analysis of tubetotubesheet welded joints. Principles of finnedtube heat exchanger design for enhanced heat transfer 2nd edition by. Failure analysis of heat exchanger tubes request pdf. This study shows the effect of various parameters such as pitch layout and baffle spacing on the heat exchanger performance. Paper open access related content reliability analysis on a.
The tubes in a heat exchanger are tested by insertion of a probe the full tube length. Fatigue started at initial defects of the welded joint was con. According to the heat exchanger design manual, when the ratio of the. This paper presents a failure analysis performed to investigate the leak of heat exchanger tubes. The us chemical safety board investigates industrial accidents in the chemical industry, providing analysis that can be used to promote and. Tube side medium in this heat exchanger was sour gas coming from high pressure separators and shell side. Scribd is the worlds largest social reading and publishing site. A failure analysis of air heat exchanger based on modal.
Process fluid assignments to shell side or tube side. Failure analysis was carried out on a tube totubesheet welded joint of a shell tube heat exchanger to confirm its failure mechanism. Design optimization of shell and tube heat exchanger by vibration analysis. Satynarayana rao2 research scholar, osmania university1, retd. 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. Failure analysis of shell and tube heat exchangers raj kulsange mis no121524006 under guidance of. Shell and tube heat exchangers are having special importance in boilers,oil coolers, condensers, preheaters. As its name implies, this type of heat exchanger consists of a shell a large tube surrounding a bundle of tubes. However, many companies have discovered that this type of heat exchanger is sensitive to metal fatigue. Shell and tube style heat exchangers are the most common kind of heat exchangers used in industries. Analysis of chemical plant heat exchanger explosion. Paper open access related content reliability analysis on. There are various causes by which heat exchanger may fail.
Common causes of heat exchanger failure november 2, 2018. Analysis of chemical plant heat exchanger explosion youtube. 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 tubetotubesheet welded joints in a. The shell and tube heat exchanger is equipment largely used at chemical industries. In addition, we will examine various aspects of heat exchanger design and analysis.
Design and analysis of a heat exchanger with helical baffles. Thorough failure analysis showed that sulfur was obviously detected on both tube side surfaces od and id. Pdf enhancement of heat transfer through shell and tube exchangers stills taking high attention by researchers. Failure analysis of cracks occured on ss304l tubes of shell. Specific operating conditions make it possible to consider and simulate the operating terms and failure conditions of these converters. Shellandtube heat exchangers are one of the most important and commonly used process equipment items in the chemical process industries cpi. The collected evidence suggests that the failure of the tube totubesheet welded joint was induced by fatigue. In present day shell and tube heat exchanger are the most common type heat. Accelerometer and microphone positions in the heat exchanger. 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. Pdf performance analysis of shell and tube heat exchanger.
The tube material was made of sa 249 tp 304l, a standard specification for welded austenitic stainless steel tubes. 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. E1mnl032a design and rating of shell and tube heat. 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. In hocl, a shell and tube heat exchanger is used in the production line of phenol. This heat exchanger is used to transfer heat from steam on the shell side to slurry on the tube side. Heat exchanger ppt free download as powerpoint presentation. In this type of heat exchanger one tube sheet is fixed relative to the shell, while. Fiorentin, et al noise and vibration analysis of a heat exchanger. Exchanger analysis and design therefore involve both convection and conduction.
Failure analysis and optimisation of tube water cooler of. In thermal systems, heat exchangers are used to control the operating temperature of the working fluids. Baffles are provided in the shell to direct the fluid flow and support the tubes. The transfer of heat takes place through the surface of the tubes. Failure analysis of heat exchanger tubes in the indirect aircooled rotary shell 297 operates above capacity limits will cause deterioration to the tubes. This tube type lubricating oil heat exchanger adopts the logarithmic mean temperature. Abstractthis paper deals with the failure analysis of air heat exchanger. Shell and tube cooler shell and tube heat exchanger consists of a bundle of tubes enclosed in a cylindrical shell. A heat exchanger can be designed by the lmtd when inlet and out let conditions are specified. Click here to get a preliminary idea about shell and tube heat exchangers. Plate type heat exchanger this is constructed by a series of corrugated parallel plates held firmly together between frames. Failure analysis of shell and tube heat exchanger free download as word doc. 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.
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. The mechanical design of a shell and tube heat exchanger provides information on items such as shell thickness, flange thickness, etc. Failure analysis of heat exchanger tubes springerlink. Design optimization of shell and tube heat exchanger by. Pdhonline course m371 2 pdh shell and tube heat exchangers. 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. 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. Shell and tube heat exchangers are one of the most commonly used type of heat exchangers in the industry for heat exchange purpose. 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. Design optimization of shell and tube heat exchanger by vibration analysis shravan h. 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. The main reason for tube failure due to flow induced vibration is increased size of sthe.
The exchangers exhibit more than 65% of the market share with a variety of design experiences of about 100 years. Dozens of leak points were found near the tubetotubesheet welded joints of the shelltube heat exchanger. To determine the cause of the failure, analysis and. Ppt on failure analysis of shell and tube heat exchangers 1. 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. Two important problems in heat exchanger analysis are i rating existing heat exchangers and ii sizing heat exchangers for a particular application. Failure analysis of stainless steel heat exchanger tubes. In this work, shell and tube heat exchanger performance analysis is performed using cfd tools under industrycollected boundary conditions. Collection and analysis of commoncause failures of heat. Most metal erosion problems occur inside the tubes. The failure analysis of shell and tube heat exchanger at hocl is done. In this white paper, we show that fatigue problems can be. To commission a new design requires regulatory approval.
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