MODELING AND ANALYSIS OF HEAT EXCHANGER

A mini project (PROJECT I) report submitted to

Jawaharlal Nehru Technological University Hyderabad

in partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
Submitted By
O. KAMAL (22WJ5A0362)
K. RITHIK (22WJ5A0339)
K. TARUN (22WJ5A0337)
Under the Guidance of

DR.M. PRAKASH
BABU

M. TECH, PHD

DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK INSTITUTIONS TECHNICAL CAMPUS

(AUTONOMOUS)
(Affiliated to JNTU, Hyderabad, Approved by AICTE, New
Delhi) Ibrahimpatnam, Ranga Reddy District-501506
Telangana, India.

2023-2024

i
 CERTIFICATE

This is to certify that the Major-Project entitled “MODELING AND

ANALYSIS OF HEAT EXCHANGER” is being submitted by O. KAMAL
(22WJ5A0362) K. RITHIK (22WJ5A0339) K. TARUN (22WJ5A0337), in
partial fulfillment for the award of the Degree of Bachelor of Technology
in Mechanical Engineering to the Jawaharlal Nehru Technological
University is a record of bonafide work carried out by them under my
guidance and supervision. The results embodied in this Minor-Project
report have not been submitted to any other University or Institute for
the award of any Degree or Diploma.

Internal guide Head of the department

Dr.M. PRAKASH BABU, M. TECH, PHD (MECHANICAL
ENGINEERING)

ii
External Examiner

iii
 DECLARATION

We declare that this Minor-Project report titled “MODELING AND

ANALYSIS OF HEAT EXCHANGER “submitted partial fulfillment for the
award of the Degree of Bachelor of Technology in Mechanical
Engineering to the Guru Nanak Institutions Technical Campus,
Ibrahimpatnam is a record of original work carried out us under the
guidance of Dr. M. Prakash Babu(M.TECH,PHD), Department of
Mechanical Engineering, and has not formed the basis for the award of
any other degree or diploma, in this or any other Institution or
University. In keeping with the ethical practice in reporting scientific
information, due acknowledgement has been made whenever the
findings of others have been cited.

O. KAMAL (22WJ5A0362)

K. RITHIK (22WJ5A0339)

K. TARUN (22WJ5A0337)

iv
 ACKNOWLEDGEMENT

We wish to express our sincere thanks to Dr. H.S SAINI, Managing

Director, Guru Nanak Institutions and Dr. S. SREENATHA REDDY, Director,
Guru Nanak Institutions Technical Campus, School of Engineering and
Technology, for providing us with all the necessary facilities and their
support.

We place on record, our sincere thanks to Dr. A. RAJ KUMAR, Professor

and Head of the Department, Mechanical Engineering for their
wholehearted co-operation, providing excellent lab facility, constant
encouragement and unfailing inspiration.

We would like to say sincere thanks to Mr. V. SHYAMU, Assistant

Professor, Department of Mechanical Engineering for coordinating
Projects. We would like to say sincere thanks to our guide DR.M. PRAKASH
BABU (M.TECH,PHD),Department of Mechanical Engineering for
Coordinating Projects for the suggestions and constant guidance in every
stage of the project, we also like to thank all our lecturers helping us in
every possible way. On a more personal note, we thank our beloved
parents and friends for their moral support.

during our project.

O. KAMAL (22WJ5A0362)

K. RITHIK (22WJ5A0339)

K. TARUN (22WJ5A0337)

v
 ABSTRACT

Shell and tube heat exchangers in their various construction

modifications are probably the most widespread and commonly used
basic heat exchanger configuration in the process industries. The
modelling of the heat exchanger has done by using the advanced design
software CATIA. In this project the Heat Exchanger is modelled and
assembled with the help of CATIA, and the component is meshed, and
analysis is done in ANSYS software, and the thermal and static behaviour
is studied, and the results are tabulated. The various stresses acting on
the Heat Exchanger under various loading conditions has been studied.
In the preset work has been taken up on the following aspects to cover
the research gaps and to present the results based on the systematic
studies. Temperature distribution and heat flow through the Heat
Exchanger. FEA analysis of the Heat Exchanger to measure temperature
at the points where it is not possible to find out practically and to
observe the heat flow inside the Heat Exchanger.

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Contents
ABSTRACT...................................................................................................................................................3

CHAPTER 1..................................................................................................................................................4

1.0 INTRODUCTION.........................................................................................................................4

1.1 ABOUT HINDUSTAN ORGANIC CHEMICALS LIMITED...........................................................4

1.2 COCHIN UNIT....................................................................................................................................5

1.3 Parts And Components........................................................................................................................7

CHAPTER 2..................................................................................................................................................8

2.0 HEAT EXCHANGERS.................................................................................................................8

2.1 COMPONENTS OF HEAT EXCHANGERS...............................................................................8

2.2 TYPES OF HEAT EXCHANGER....................................................................................................10

2.3 .Direct Contact Heat Exchangers.......................................................................................................10

2.4 Indirect Contact Heat Exchangers....................................................................................................11

2.5 . DESIGN AND CONSTRUCTIONAL FEATURES.......................................................................15

2.6 . PHYSICAL STATE OF FLUIDS...................................................................................................16

2.7 OPERATION OF HEAT EXCHANGER.........................................................................................17

2.8. MAINTENANCE OF HEAT EXCHANGER..................................................................................18

2.9 FOULING..........................................................................................................................................20

2.10 TYPES OF SERVICES...................................................................................................................25

2.11 TYPES OF FAILIURE....................................................................................................................26

CHAPTER 3................................................................................................................................................35

3.0 SPECIFICATION OF HEAT EXCHANGER PARTS.....................................................................35

3.1 THE CHANNEL COVER.................................................................................................................35

CHAPTER 4................................................................................................................................................45

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 4.0 INTRODUCTION TO CATIAV5R16..............................................................................................45

4.1 Drafting..............................................................................................................................................55

CHAPTER 5................................................................................................................................................56

5.0 Introduction to ANSYS:....................................................................................................................56

5.1 MODAL ANSYS:..............................................................................................................................56

5.2 Static Analysis...................................................................................................................................57

5.3 STATIC STRUCTURAL ANALYSIS..............................................................................................62

5.4 THERMAL ANALYSIS...................................................................................................................63

CHAPTER 6................................................................................................................................................66

6.0 CHECKING THE DESIGN..............................................................................................................66

6.0.1.Constructional details..................................................................................................................66

CONCLUSION............................................................................................................................................71

REFERENCES............................................................................................................................................72

8
 ABSTRACT
Shell and tube heat exchangers in their various construction modifications are probably the most
widespread and commonly used basic heat exchanger configuration in the process industries.
The modelling of the heat exchanger has done by using the advanced design software CATIA. In
this project the Heat Exchanger is modelled and assembled with the help of CATIA and the
component is meshed and analysis is done in ANSYS software and the thermal and static
behaviour is studied and the results are tabulated. The various stresses acting on the Heat
Exchanger under various loading conditions has been studied. In the preset work has been taken
up on the following aspects to cover the research gaps and to present the results based on the
systematic studies. Temperature distribution and heat flow through the Heat Exchanger. FEA
analysis of the Heat Exchanger to measure temperature at the points where it is not possible to
find out practically and to observe the heat flow inside the Heat Exchanger.

In the preset thesis work has been taken up on the following aspects to cover the
research gaps and to present the results based on the systematic studies:
1) Temperature distribution and heat flow through the Heat Exchanger.
2) FEA analysis of the Heat Exchanger to measure temperature at the points where it is not
possible to find out practically and to observe the heat flow inside the Heat Exchanger.

9
 CHAPTER 1
1.0 INTRODUCTION
We look up a project on heat exchanger, which is static equipment at Hindustan organic
chemicals limited. Heat exchanger may be defined as equipment which transfers the energy
from a hot fluid to a cold fluid with maximum rate and minimum investment and running cost.

It is used to reduce temperature of one process fluid, which is desirable cool ,by
transferring heat to another fluid which is desirable to heat without inter mixing the fluid or
changing the physical state of the fluid.

Heating is a vital operation in the petroleum and chemical refinery. Hence failure of a
heat exchanger result ineffective transfer of energy. Normal operation of heat exchanger usually
requires little operator attention .However, operating life of a heat exchanger can be drastically
curtailed by improper start up and shut down practices. So properly planed executed
maintenance schedule is in dispensable for very industries having heat exchangers on their main
equipment in their process plant.

A detailed maintenance schedule of plant and machinery of an industry involves mainly

monitoring without disturbing the operation of the plant as a whole.

A project titled "Failure analysis of shell and tube heat exchanger" presents an over view
on different types of heat exchangers, their purposes advantages and disadvantages and the
maintenance procedure adopted for smooth operation of the heat exchanger. The operation of
heat exchanger involves the production of phenol from TAR COLUMN.

The case study deals with the failure analysis of heat exchanger and design is checked
and then proper solutions are given to improve the effectiveness of heat exchanger.

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1.1 ABOUT HINDUSTAN ORGANIC CHEMICALS LIMITED
The HOCL was in-corporate with a view to Set up manufacturing of chemical
intermediates with the objectives of giving inputs to the development of downstream industrial
units in sector like dyes and dye intermediates, drugs and pharmaceuticals, rubber chemicals,
laminations, solvents etc. The first unit was set up at Rasayani in Maharashtra which
commenced production in 1970. The second unit was started at Cochin in Kerala, which started
production in 1987. In the year 1988 a subsidiary company viz Hindustan fluorocarbons Ltd.
was commissioned at Hyderabad. The company is presently engaged in the manufacturing of a
wide range of petrochemicals. The major products serve as import substitutes.

The HOCL is a public limited company, which is managed by a board of directors

consisting of six members.

The management is assisted by a team of well qualified and experienced professionals in

technical financial safety, marketing, legal and other key areas.

1.2 COCHIN UNIT

Commissioning of Cochin (phenol and acetone) in 1987 headed another path breaking
step of HOCL entry into the field of petrochemicals. The Cochin plant has an installed capacity
of 24,000 TPA of acetone and 409000 TP A of phenol; both are highly versatile organic
chemicals.

The Cochin unit comprises of three states of plant, Viz.

1) Propylene recovery plant

2) Cymene plant
3) Phenol plant
4) Hydrogen peroxide

Universal oil products Inc (UOP\ USA One of the] world leaders in the field of
petrochemicals has supplied the technology for phenol-cumene plant. Detailed engineering for
all the plants and also off-site work was done by FEDO and Engineers Indian Ltd. Provided
engineering for the propylene plant and Effluent treatment plant.

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 The company has achieved the ISO 9002 certification for its quality measures in the
production process and ISO 14,000 for environmental quality standards. The entire operation of
plant is totally Automatic remote controlled. Continuous on-line monitoring of the process
results in perfect quality control

The organization has high tech safety features to minimize hazards. Most modem effluent
treatment plant assures complete safety to the environment confirming to international
specifications. Latest energy conservation and optimization concepts have been incorporated at
the beginning stage. This is the first company to export Phenol and Acetone from India State
pollution control board has awarded the company with the certificate of merit for pollution
control. Cochin plant was awarded with the best pollution control measures among chemical
plants in the state of Kerala

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1.3 Parts and Components

1) H2 02 plant
2) Main tank age
3) H2 plant 1
4) Compressor house
5) DM plant
6) Boiler
7) H2Plant2
8) North Tankage
9) Fractionation section
10) Hot oil plant
11) Tar cracking plant
12) Cumox plant
13) Cymene plant
14) South tankage
15) Cymene storage
16) Effluent treatment plant
17) Cymene storage
18) Main receiving station
19) Captive power plant
20) Main control room
21) Propylene plant
22) Propylene storage
23) LPG storage
24) Cooling tower
25) Administrative block
26) Pre-treatment plant
27) Water storage
28) Emergency escape road.

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 CHAPTER 2

2.0 HEAT EXCHANGERS

Heating, Condensing and Cooling are operations vital to the petroleum and chemical
refinery. These operations are accomplished mainly by tubular exchanger equipment (Shell and
Tube). Other equipments used for condensing and cooling are air cooled heat exchanger and
box coolers.

A heat exchanger may be defined as equipment which transfers the energy from the hot fluid
to a cold fluid or vice versa, with maximum rate and minimum investment and running cost.
The heat exchanger is used to reduce the temperature of one process fluid, which is desirable to
heat without interred mixing the fluids or changing the physical state of the fluids. Condensers
are used to cool the temperature of a process vapors to the point where it will become a liquid
by the transfer of heat to another fluid without intermixing the fluids. Water or air is used to
condense the vapors.

In HOCL heat exchangers are mainly used for condensing the hot vapors of the product
obtained by crude distillation and storing them in the liquid form.

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COMPONENTS OF HEAT EXCHANGERS

The figure given below shows a typical heat exchanger and its components

1. Stationary Head-Channel 16. Floating Head Cover

2. Stationary Head-Bonnet 17. Floating Head Flange
3. Stationary Head Flange 18. Floating Head Baring Device
4. Channel Cover 19. Split Shear Ring
5. Stationary Head Nozzle 20. Slip-On Backing Flange
6. Stationary Tube sheet 21. Floating Head Cover-
7. Tubes External
8. Shell 22. Floating Tube Sheet Skurt
9. Shell cover 23. Packing Box
10. Shell Flange 24. Packing
11. Shell flange- Read Head End 25. Packing Gland
12. Shell Nozzle 26. Lantern Ring
13. Shell Cover Flange 27. Tierods and Spacers
14. Expansion joint 28. Transverse Baffles/support
15. Floating Tubes sheet Plates

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2.2 TYPES OF HEAT EXCHANGER
In order to meet the widely varying applications several types of heat exchangers have been
developed which are classified on the basis of nature of heat exchange process, relative
direction of fluid motion, design and constructional features and physical state of fluids.

Nature of Heat Exchange Process:

Heat exchangers on the basis of nature of heat exchange process are classified as.

1. Direct contact opened heat exchangers.

2. Indirect contact heat exchangers.
a. Regenerators.
b. Recuperated

2.3 .Direct Contact Heat Exchangers

Figure.2

DIRECT CONTACT HEAT EXCHANGER

In a direct contact heat exchanger, exchange of heat takes place by direct mixing
of hot and cold fluids and transfer of heat and mass takes place simultaneously. The use
of such units is made under conditions where mixing of two fluids is either harmless or
desirable.

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2.4 Indirect Contact Heat Exchangers

In this type of heat exchangers, the heat transfer between two fluids could be carried out
by transmission through wall which separates the two fluids.

a. Regenerator

In a regenerator type of heat exchangers the hot and cold fluids pass alternatively
through a space containing solid particles (matrix), these particles providing alternatively
a sink and a source for heat flow.

E.g.: IC Engine & Gas Turbine.

The performance of these regenerators is affected by the following parameters

1. Heat capacity of Regenerating Materials.

2. The rate of absorption
3. The release of heat.

Advantages of regenerators are :

1. Higher heat transfer coefficient.

2. Less weight per KW of the plant.
3. Minimum pressure loss
4. Quick response to load variations
5. Small bulk weight.

Disadvantages of regenerators are:

1. Costlier compared to recuperative heat exchangers.

2. Leakage is the main trouble; therefore, perfect sealing is required.

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b. Recuperators

Recuperator is the most important type of heat exchanger in which the following fluids
exchanging heat are on either side of dividing wall. These heat exchangers are used when two
fluids cannot be allowed to mix i.e., when the mixing is undesirable.

e.g: - 1. Oil Coolers, Intercoolers, 2. Automobile radiators.

Advantageous of a recuperator are.

1. Easy construction
2. More economical
3. More surface area for heat transfer.
4. Much suitable for stationary plants.

2. Relative Direction of fluid motion

According to relative directions of two fluids streams the heat exchangers are classified into
following three categories.

 Parallel flow or unidirectional flow.

 Counter flow.
 Cross flow

i. Parallel flow heat exchanger.

In parallel flow heat exchanger as the name suggest the two fluid streams (hot and cold)
travel in the same direction. The two streams enter at one end and leave at the other end. The
flow arrangements and variations of temperatures of the fluid stream in case parallel flow heat
exchangers are shown in figure. It is evident from the figure that the temperature difference
between the hot and the cold fluid goes on decreasing from inlet to outlet. Since this type of
heat exchangers needs large areas of heat transfer it is rarely used in practice.

Example: oil coolers, oil heaters, water heaters

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 As the two fluids separated by a wall, this type of heat exchanger may be called parallel flow
recuperated or surface heat exchanger.

FIGURE 3: Temperature distribution along tube axis.

ii. Counter Flow Heat Exchanger.

In a counter flow heat exchanger, the two fluid flow in opposite direction. The hot and cold
fluid enters the opposite ends. The flow arrangements and temperature distribution for such a
heat exchanger are shown in figure. The temperature difference between the fluids remains
more or less nearly constant. This type of heat exchanger due to counter flow gives maximum
rate of heat transfer for a given surface area. Hence such heat exchangers are most favored for
heating and cooling fluids.

ii. Cross Flow Heat Exchanger

In cross flow heat exchangers the two fluids (hot and cold) cross one another in space
usually at right angles.

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 Fig.5 shows a schematic diagram of common arrangements of cross flow heat exchangers.

Hot fluid flow in the separate column and there is mixing in the fluid streams. The cold fluid
is perfectly mixed as its flow through the exchanger. The temperature of this mixed fluid will be
uniform across any section, and will vary only in the directions of the flow. Example: cooling
unit of refrigeration system. Refer figure: In this case each of the fluid follows a prescribed path
and is unmixed as it flows through heat exchanger. Hence the temperature of the fluid leaving
the heater section is not uniform.

Example: automobile radiator

2.1 Design and Constructional Features:

On the basis of design and constructional features, the heat exchanger are classified as under

i. Concentric Tubes

In this type, two concentric tubes are used each carrying one of the fluids. The direction flow
may be parallel or counted as depicted in figure. The effectiveness of the heat exchanger is
increased by using swirling flow.

ii. Shell and Tube

In this type of heat exchanger one of the fluid flows through a bundle of tube enclosed by a
shell. The other fluid is forced through the shell and it flows over the outside of surface of the
tubes. Such an arrangement employed where reliability and heat transfer effectiveness are
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 important. With the use of multiple tubes heat transfer rate is amply improved due to increased
surface area.

iii. Multiple Shell and Tube Passes

Multiple shell and tube passes are used for enhancing the overall heat transfer. Multiple shell
passes is possible where the fluid flowing through the shell is re-routed. The shell side fluid is
forced to flow back and forth across the tubes in the by baffles. Multiple tube pass exchangers
are those which re-route the fluid through tubes opposite direction

HOT FLUID OUT

iv. Compact Heat Exchanger

These are special purpose heat exchangers and have a very large transfer surface area per unit
volume of the exchanger. They are generally employed the convective heat transfer co-efficient
associated with one of the fluids is much smaller than that associated with the other fluid.

Example : Plate - Fin, flattened fin tube exchangers.

2.2. Physical State of Fluids.

Depending upon the physical state of the fluids the heat exchangers are classified as follows :

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1) Condenser
2) Evaporators
 Condenser

In a condenser, the condensing fluid remains at constant temperature throughout the

exchanger, while the temperature of colder fluid gradually increases from inlet to outlet. The hot
fluid losses latent part of fluid which is accepted by the colder fluid.

 Evaporators

In this case, the boiling fluid remains at constant temperature while the temperature of the hot
fluid gradually decreases from inlet to outlet

2.7 OPERATION OF HEAT EXCHANGER.

Normal operation of heat exchangers usually requires little operator attention. However,
operating life of a heat exchanger can be drastically curtailed by improper start up and shut
down practices.

Some common problems are:

i. Tube failure due to 'water hammer' effect caused by opening the shell inlet valve too
quickly.
ii. Bending of the pass partition plate in the partition channel due to slung flow from the
tube inlet nozzle. Caused by rapid opening of the channel inlet valve.
iii. Introduction of tube side fluid in a fixed tube sheet heat exchanger with the shell side
empty (since the resulting change in the tube metal temperature may over stress the tube
to tube sheet joint resulting in the failure).
iv. Thermal stress induced cracking of thick sections in region of gross structural
discontinuity, such as tube sheet/channel junction in integral design, due to rapid
changes in the fluid temperature. In order to avoid such problems start up and shut down
of the equipments should be carried out in a manner consistent with the original design
basis.

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 At times, heat exchangers are designed to operate under differential pressure is the shell
and the tube side pressure is always presents simultaneously. The operator should ensure that
the design assumption of differential pressure is never violated. Including the period of start up
and shut down, or the period of system pressure testing.

Other operational problems in heat exchanger are flow induced vibration, rapid tube
failure, corrosion and erosion of the tube wall, tube joint failure, fluid level control difficulties
and flanged joint leakage.

2.8. MAINTENANCE OF HEAT EXCHANGER

Operating problems in heat exchangers may be broadly classified into three groups.

i. Structural Problems
ii. Performance Problems
iii. Metallurgical problems

i. Structural Problems

Structural problems are the most serious; failure is often swift and irreversible. Failures
caused by flow - induced vibration of heat exchanger tubes over shadow all other structural
failures. Tube to tube sheet joints failure is also a frequent operational problem.

The other type of structural failure encountered in heat exchanger operation is leakage from
holted joints. Leaks frequently occurred nozzle flanges due to moment loading of the joint
caused by thermal expansion of the interconnecting piping. In some cases, non-temperature
distribution in the tube sheet or cover in multiple pass design induces joint leakage.
Replacement of the leaking gaskets with one having more appropriate loading and relaxation
properties is usually the panacea for such structural problems.

ii. Performance Problems

The excessive tube fouling usually causes performance problems Deposition of foul ants on
the inside of the tube surface reduces the available flow area and increase the skin friction,

23
causing an increase in pressure loss and decrease in heat transfer. Un even rates of fouling of
tubes usually occur in units with low flow velocity design. Uneven fouling may occur on the
shell side of the tubes due to a poor baffling scheme. Which leads to a flow misdistribution.
Highly non-uniform fouling on severely modifies the metal temperature profile in some tubes
resulting in large tubes - to tube sheet joint leads.

Thermal stresses in the internal of the heat exchanger can cause serious degradation of heat
duty. The most obvious example is failure of welds joining pass partition plates to each other
and to the channel.

iii. Metallurgical problems

Stress corrosion, galvanic corrosion, and erosion are the most frequently reported
metallurgical problems. Care in the selection of material can eliminate most of these problems.
Where the galvanic action cannot be completely eliminated. The use of waster anode is
recommended.

ADVANTAGES AND DISADVANTAGES OF HEAT EXCHANGERS

Advantages

1. Energy Savings.
2. No Additional boilers are needed.
3. Condensation provides less space and safety operations.

Disadvantages

1. The use of heat exchange causes the flow restriction, hence, additional pumps are
required to correct the flow.
2. Friction losses
3. Operation difficulties such as flange leakage.
4. Failure of heat exchanger.
5. Maintenance cost and operating cost.

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2.9 FOULING
In a heat exchanger during normal operations the tube surface gets covered by deposits of
ash, soot, and dirt and scale etc. This phenomenon of rust formation and deposition fluid
impurity is called fouling.

Fouling Processes

1. Precipitation or crystallization fouling

2. Sedimentation or particulate fouling
3. Chemical reaction fouling or polymerization
4. Corrosion fouling
5. Biological fouling
6. Freeze fouling

Parameter affecting fouling

1. Velocity
2. Temperature
3. Water chemist
4. Tube material

Prevention of fouling

The following methods may be used to keep fouling minimum

i. Design of heat exchanger

ii. Treatment of process system

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 iii. By using clean system

Properties to be considered for selection of materials for heat exchanger

1. Physical properties
2. Mechanical Properties
3. Climatic Properties
4. Chemical Environment
5. Quality of Surface finish
6. Service File
7. Freedom from Noise
8. Reliability

Common failure to heat exchangers

1. Checking of tubes either expected or extra ordinary

2. Excessive transfer rates in heat exchanger
3. Increasing the pump pressure to maintain through out
4. Failure to clean rubes at regularly scheduled intervals.
5. Excessive temperature in heat exchanger
6. Lack of control of heat exchangers atmosphere to retard scaling.
7. Increased product temperature over a safe design unit
8. Unexpected radiation from refractory surface.
9. Unequal heating around the circumferences or along the length tubes.

Overall Heat Transfer Coefficient

Heat transfer in heat exchanger takes place mainly by conduction and convection. If a tube
wall as separates the fluids shown in figure. The overall heat transfer coefficient is given by

Inner surface

Ui 1/hi + ri/k In (ro /ri) + ri/ro x 1/ho

Outer surface

26
 Uo (ro /ri) 1/hi + ro/kxln ( ro/ri) x 1/ho

Where, Ui=Overall heat transfer coefficient inside the tube

Uo= Overall heat transfer coefficient outside the tube

Hi= Local convective heat transfer coefficient inside the tube
ho= Local convective heat transfer coefficient inside the tube
ri= Inside radius of the tube
ro=Outside radius of the tube
k=Conductive heat transfer coefficient of tube material.
U.A.=UoAo
Where
A=2 r. L, Area inside the tube
A=2 r L, Area outside the tub

Consideration of fouling or scaling Due to fouling the thermal resistance is increased and
eventually the performance of heat exchangers lowers. Since it is difficult to ascertain the
thickness and thermal conductivity of the scale deposits, the effect of sale on heat flowing
considered by specifying an equivalent scale heat transfer coefficient hs.

If hsj and hsQ be the heat transfer coefficient for the scale deposited on the inside and outside
surface respectively, than the thermal resistance to scale formation on the inside surface (RSj)
and outside surface (RS0) are given by

27
2.10 TYPES OF SERVICES
There are various types of services in which tubular exchangers are used in petroleum and
chemical processes listed below.

1 .Heat Exchanger:

It used to reduce the temperature of one process fluid, which is desirable to cool by
transferring heat to another fluid which is desirable to heat without inter-mixing the fluids or
changing the physical state of the fluid.

2. Condenser:

Condenser is used to reduce the temperature of a process vapors to the point where it will
become a liquid by the transfer of heat to another fluid without intermixing the fluid. Water or
air is used to condense process vapors. The function results in a changing the physical state of
the process vapors.

3. Coolers:

They are used to cool a heat process liquid to a lower more desirable temperature by the
transfer of heat to another fluid without inter-mixing the fluid. Water or air is usually used to
cool process liquids. This function does not result in a changing physical state of the process
liquid.

28
4.Evaporator:

Evaporator is used in the vaporization of a process liquid by either a process or utility liquid
or vapor without intermixing the fluid. Many aspirators are steam to vaporize a process liquid.
This function results in a changing the physical state of the process vapors. When steam is used
condensate is usually formed.

5. Re - boilers :

Re-boilers are used in the partial vaporizations of a process fluid by either a process or utility
liquid or vapor. Many re-boilers are steam to vaporize a process liquid.

2.11 TYPES OF FAILIURE

Stress Corrosion Cracking

Stress corrosion cracking is a failure mechanism that is caused by environment, susceptible

material, and tensile stress. Temperature is a significant environmental factor affecting cracking.
For stress corrosion cracking to occur all three conditions must be met simultaneously. The
component needs to be in a particular crack promoting environment, the component must be
made of a susceptible material, and there must be tensile stresses above some minimum
threshold value. An externally applied load is not required as the tensile stresses may be due to
residual stresses in the material. The threshold stresses are commonly below the yield stress of
the material.

Stress Corrosion Cracking Failures

Stress corrosion cracking is an insidious type of failure as it can occur without an externally
applied load or at loads significantly below yield stress. Thus, catastrophic failure can occur
without significant deformation or obvious deterioration of the component. Pitting is commonly
associated with stress corrosion cracking phenomena Aluminum and stainless steel are well
known for stress corrosion cracking problems all metals are susceptible to stress corrosion
cracking in the right environment.

29
Controlling Stress Corrosion Cracking

There are several methods to prevent stress corrosion cracking. One common method is
proper selection of the appropriate material. A second method is to remove the chemical species
that promotes cracking. Another method is to change the manufacturing process or design to
reduce the tensile stresses. AMC can provide engineering expertise to prevent or reduce the
likelihood of stress corrosion cracking in your components.

Failures of Heat Exchangers

Some common causes of failures in heat exchangers are listed below:

 Pipe and tubing imperfections

 Welding
 Fabrication
 Improper design
 Improper materials
 Improper operating conditions
 Pitting
 Stress-corrosion cracking (SCC)
 Corrosion fatigue
 General corrosion
 Crevice corrosion
 Design errors
 Selective leaching, or dealt
 Erosion corrosion

Wear Failures

30
 Wear may be defined as damage to a solid surface caused by the removal or displacement of
material by the mechanical action of a contacting solid, liquid, or gas. It may cause significant
surface damage and the damage is usually thought of as gradual deterioration. While the
terminology of wear is unresolved, the following categories are commonly used.

Adhesive wear

Adhesive wear has been commonly identified by the terms galling, or seizing

Abrasive wear

Abrasive wear, or abrasion, is caused by the displacement of material from a solid surface
due to hard particles or protuberances sliding along the surface

Erosive wear

Erosion, or erosive wear, is the loss of material from a solid surface due to relative motion in
contact with a fluid that contains solid particles. More than one mechanism can be responsible
for the wear observed on a particular part.

Pitting Corrosion

Pitting is a localized form of corrosive attack. Pitting corrosion is typified by the formation of
holes or pits on the metal surface. Pitting can cause failure due to perforation while the total
corrosion, as measured by weight loss, might be rather minimal. The rate of penetration may be
10 to 100 times that by general corrosion.

31
 Pits may be rather small and difficult to detect. In some cases pits may be masked due to
general corrosion. Pitting may take some time to initiate and develop to an easily viewable size.
Pitting occurs more readily in a stagnant environment. The aggressiveness of the corroding will
affect the rate of pitting.

Some methods for reducing the effects of pitting corrosion are listed below:

•Reduce the aggressiveness of the environment

•Use more pitting resistant materials

Uniform Corrosion

Uniform or general corrosion is typified by the rusting of steel. Other examples of uniform
corrosion are the tarnishing of silver or the green patina associated with the corrosion of copper.
General corrosion is rather predictable. The life of components can be estimated based on
relatively simple immersion test results. Allowance for general corrosion is relatively simple
and commonly employed when designing a component for a known environment.

Some common methods used to prevent or reduce general corrosion are listed below:

 Coatings
 Inhibitors
 Cathode protection
 Proper materials selection

Corrosion Failures

Corrosion is chemically induced damage to a material that results in deterioration of the

material and its properties. This may result in failure of the component. Several factors should
be considered during a failure analysis to determine the affect corrosion played in a failure.

Examples are listed below:

 Type of corrosion
 Corrosion rate
 The extent of the corrosion

32
  Interaction between corrosion and other failure mechanisms

Corrosion is a normal, natural process. Corrosion can seldom be totally prevented, but it can
be minimized or controlled by proper choice of material, design, coatings, and occasionally by
changing the environment. Various types of metallic and nonmetallic coatings are regularly
used to protect metal parts from corrosion.

Stress corrosion cracking

Necessitates a tensile stress, which may be caused by residual stresses, and a specific
Environment to cause progressive fracture of a metal. Aluminum and stainless steel are well
known for stress corrosion cracking problems. However, all metals are susceptible to stress
corrosion cracking in the right environment.

Laboratory corrosion testing is frequently used in analysis but is difficult to correlate with
actual service conditions. Variations in service conditions are sometimes difficult to duplicate in
laboratory testing.

Corrosion Failures Analysis

Identification of the metal or metals, environment the metal was subjected to, foreign matter
and/or surface layer of the metal is beneficial in failure determination. Examples of some

common types of corrosion are listed below:

 Uniform corrosion
 Pitting corrosion
 Inter-granular corrosion
 Crevice corrosion
 Galvanic corrosion
 Stress corrosion cracking

Not all corrosion failures need a comprehensive failure analysis. At times a preliminary
examination will provide enough information to show a simple analysis is adequate.

Fatigue Failures

33
 Metal fatigue is caused by repeated cycling of the load. It is a progressive localized damage
due to fluctuating stresses and strains on the material. Metal fatigue cracks initiate and
propagate in regions where the strain is most severe.

The process of fatigue consists of three stages:

 Initial crack initiation

 Progressive crack growth across
 Final sudden fracture of the remaining cross section

Stress Ratio

The most commonly used stress ratio is R, the ratio of the minimum stress to the maximum
stress (Smin/Smax).

 If the stresses are fully reversed, then R = -1.

 If the stresses are partially reversed, R = a negative number less than 1.
 If the stress is cycled between a maximum stress and no load, R = zero.
 If the stress is cycled between two tensile stresses, R = a positive number less than 1.

34
 Variations in the stress ratios can significantly affect fatigue life. The presence of a mean
stress component has a substantial effect on fatigue failure. When a tensile mean stress is added
to the alternating stresses, a component will fail at lower alternating stress than it does under a
fully reversed stress.

Preventing Fatigue Failure

The most effective method of improving fatigue performance is improvements in design:

 Eliminate or reduce stress raisers by streamlining the part

 Avoid sharp surface tears resulting from punching, stamping, shearing, or other
processes
 Prevent the development of surface discontinuities during processing.
 Reduce or eliminate tensile residual stresses caused by manufacturing.
 Improve the details of fabrication and fastening procedures

Fatigue Failure Analysis

Metal fatigue is a significant problem because it can occur due to repeated loads below the
static yield strength. This can result in an unexpected and catastrophic failure in use. Because
most engineering materials contain discontinuities most metal fatigue cracks initiate from
discontinuities in highly stressed regions of the component. The failure may be due the
discontinuity, design, improper maintenance or other causes. A failure analysis can determine
the cause of the failure.

35
High Temperature Failure Analysis

Creep occurs under load at high temperature. Boilers, gas turbine engines, and ovens are
some of the systems that have components that experience creep. An understanding of high
temperature materials behavior is beneficial in evaluating failures in these types of systems.
Failures involving creep are usually easy to identify due to the deformation that occurs. Failures
may appear ductile or brittle. Cracking may be either transgranular or intergranular. While creep
testing is done at constant temperature and constant load actual components may experience
damage at various temperatures and loading conditions.

Creep of Metals

High temperature progressive deformation of a material at constant stress is called creep.

High temperature is a relative term that is dependent on the materials being evaluated.

A typical creep curve is shown below:

In a creep test a constant load is applied to a tensile specimen maintained at a constant

temperature. Strain is then measured over a period of time. The slope of the curve, identified in
the above figure, is the strain rate of the test during stage II or the creep rate of the material.

Primary creep, Stage I, is a period of decreasing creep rate. Primary creep is a period of
primarily transient creep. During this period deformation takes place and the resistance to creep
increases until stage II. Secondary creep, Stage II, is a period of roughly constant creep rate.
Stage II is referred to as steady state creep. Tertiary creep, Stage III, occurs when there is a
reduction in cross sectional area due to necking or effective reduction in area due to internal
void formation.

36
Stress Rupture

Stress rupture testing is similar to creep testing except that the stresses used are higher than
in a creep test. Stress rupture testing is always done until failure of the material. In creep testing
the main goal is to determine the minimum creep rate in stage II. Once a designer knows the
materials will creep and has accounted for this deformation a primary goal is to avoid failure of
the component.

Stress rupture tests are used to determine the time to cause failure. Data is plotted log-log as
in the chart above. A straight line is usually obtained at each temperature. This information can
then be used to extrapolate time to failure for longer times. Changes in slope of the stress
rupture line are due to structural changes in the material. It is significant to be aware of these
changes in material behavior, because they could result in large errors when extrapolating the
data.

37
 CHAPTER 3

SPECIFICATION OF HEAT EXCHANGER PARTS

3.1 THE CHANNEL COVER

Channel covers are usually circulars in design and fabricated out of the same plate material
as the channel. The thickness of the flat channel covers in determined from code or TEMA
formulas whichever is greater. For single pass channels or other in which there is no pass
partition gasket seal against the channel cover. Only the code formula needs be considered. The
effective thickness of the flat channel covers is the thickness measured at the bottom of the pass
partition grove minus the tube side corrosion allowance in excess of the grove depth. Channel
covers are required to be provided with approximately 3/16 “(408m) deep groves for pass
partition plates.

3.2 THE CHANNEL

The channel is usually rod plate material with the edges welded together by a full penetration
fusion weld. This weld is a longitudinal seam. The stationary flanges of the channel are welded
in the same manner are circumferential weld seam. The pass partitions in the channel are flat
plate and the same material as the channel. They are usually attached to the inside of channel by
fall penetration fusion weld. The nominal thickness of channel pass partitions shell not be less
than that shown in the table given below. Partition plates may be tapered to gasket width at the
contact surface.

38
THE SHELL

Construction and fabrication of an exchanger are similar to that of pressure vessel. The
exchanger's shell material is usually rolled plate material. The plate edges are welded together
by a full penetration fusion weld. This weld is the longitudinal weld seam. The exchanger may
require two or more shell rings joined together to form a single exchanger shell. The welds
joining the rings together are circumferential weld seams. For small diameter exchangers,
seamless pipe is usually used. The shell thickness of the exchanger is determined by code
design formulas plus corrosion allowance, but is no case shall the nominal thickness of the shell
be less than that shown in the TEMA table given below.

39
 For AES exchangers and the other types of exchanger’s flanges are in accordance with code
design rules. Flanges are through-bolted type unless otherwise specified. The shell flange to
shell welds is circumferential weld seams and is also full penetration fusion welds.

Note:

All weds on the inside of the exchanger shell are ground flush with the base material so the
tube bundle with slide in and out of the shell without hanging up.

SHELL COVER

The shell cover thickness is determined by code design formulas plus corrosion allowance.
For shell covers, TEMA requires the thickness of the shell cover to be at least equal to the
thickness of the shell cover to be least equal to the thickness of the shell as shown given
previous page. The material used to fabricate the shell cover is the same as the shell material.
The body of the shell cover is usually roved plate material with the edges together with a full
penetration fusion weld. The head used for the shell cover is normally a flanged and dished
type. Both the head the flange are welded to the body of the head with a full penetration fusion
weld.

NOZZLES

Nozzles may be fabricated out of pipe coupling, built up construction, long weld neck flanges
as integrally reinforced nozzles. The integrally reinforced necks are preferred. Shed nozzles are
not permitted to protrude beyond the inside contour of the shell. Channel nozzles may protrude
inside the channel, provided vent and drain connections are flush with the inside contour of the
channel. Vents and drains on the shell side of the exchanger not otherwise vented or drained by
nozzles are required to have a 3/4" connections may be provided at the manufacturers obtain.
Flat on raised flanges are required between intermediate nozzles of stacked units. Bolting in
flanges of mating connections between stacked exchangers is required to be removable without

40
moving the exchangers. All nozzles are required to be full penetration fusion welds with the
inside of the weld to be flush on all shell connections.

TUBE SHEETS

The tube bundle of the AES exchanger has a stationary tube sheet on the channel end of the
bundle and a floating head tube sheet on the back end of the bundle. The diameter of the
floating head tube sheet is small enough to pass through the cylindrical shell. The diameter of
the stationary tube sheet is larger enough to bear on a gasket surface of the shell flange
stationary end. Tube sheets may be the same material as the tubes or may be of a different
metallurgy that the tube. Because of economics a cooler or condenser may have brass tubes and
carbon steel tube sheet. From corrosion standpoint it is not good to mix metallurgy like this in
water service because of galvanic corrosion between the brass tube and carbon steel tube sheet.
Life of the carbon steel tube sheet can be extended by adding cathode protection in the channel
and the floating head during fabrication or after the unit arrives at the refinery. Tube sheets may
also be alloy lined by cladding or weld metal overlay for corrosion resistance. Cladding should
be integrally and continuously bonded to the base material of the tube sheet and is not counted
for the strength is adds to the base material.

The TEMA nominal cladding thickness on the tube side face of a tube sheet is to be note
than 5/16" (8mm) when tubes are expanded only, and 1/8" when tubes are welded to the tube
sheet. The nominal cladding thickness of the shell side face shall not be less than 3/8". All
surfaces exposed to the fluid including gasket seating surfaces, are required to have at least 1/8"
nominal thickness of cladding. The circular tube sheets are machined to the required dimensions
including gasket seating surfaces. Tube holes are drilled and reamed for the tubes. If the tube
sheets require heat treatment, the final whole size is obtained by reaming after heat treatment.
Tubes are usually attached to the tube sheet by rolling. A suitable roller type tube expander
should be used to tighten tube. Care must be taken to insure that the tubes are not over
expanded, thus avoiding possible damages to the tube.

All tube sheet tube holes for expanded joints are required by TEMA to have at least two
machined grooves each, approximately 1/8" (3mm) wide by 1/64" deep. Tubes are normally
expanded into the tube sheet for a length not less than 2" or tube sheet thickness minus 1/8"

41
whichever is smaller. In no case should the expanded portion of the tube extend beyond the
shell side face of the tube sheet. The expanding procedure should provide uniform expansion
throughout the expanded portion of the tube without sharp transition to the unexpanded portion.
Tubes for the top tube sheet in vertical exchangers are required to be flush to facilitate drainage.
Tubes may also be rolled and seal welded for additional leak tightness or strength welded.

BAFFLES AND TUBE SUPPORTS

Baffles are used to channel the shell side fluid around the tubes from the shell inlet to the
shell outlet. The various types of baffles used in tube bundle construction are illustrated in
figure. The segmental or multi-segmental type of baffles or tube support plate is standard, but
other type of baffles may be used. The baffles are circular plate with a segment opening and the
height of this opening is a percentage of the shell inside diameter.

The baffle material may be the same as the shell or tube material, depending on what was
specified by the purchaser. Baffles tube holes are usually drilled into the baffles. When the
maximum unsupported tube length is 914 mm or less, or tubes larger in diameter than 33 mm
diameter and greater, standard tube holes are drilled 0.4 mm over the outer diameter of the
tubes. For pulsating conditions, tube holes may be drilled smaller than standard. All baffle holes
drilling has a maximum over tolerance of 0.25 mm.

42
 The design inside diameter of the pipe shell is the nominal outside diameter of the pipe,
minus twice the nominal wall thickness. The design inside diameter of a plate shell is the
specified inside diameter, Special design consideration must be given to baffles and support
plates subjected to pulsations, to baffles and support plates engaging tubes, and to longitudinal
baffles subjected to large differential pressures due to high shell side fluid pressure drops.
Baffles and support plate spacing are normally spaced uniformly, spanning the effective tube
length. When the design is such that this cannot be done, the baffles nearest the ends of the
shell are and tube sheets are located as close as practical to the shell nozzles. The remaining
baffles are then spaced uniformly.

THE RODS AND SPACERS

The baffles or support plates of a bundle are tied together with tie rods and spacers. They
hold the baffles or supports securely in position during the fabrication of the bundle. The tie
rods are normally rod material and the spacers tubing. The material of both should be similar to
that of the tubes. In some cases, because of economic, some refineries have carbon still tie rods
and spacers in a brass tube bundle.

SEALING DEVICES

In addition to baffles it may be necessary to prevent excessive fluid by passing around or

through the tube bundle that has a longitudinal baffle or baffles, particularly in the case of type
F, G, H or J shells. The most common sealing device is seal strips but tie rods with spacers,
dummy tubes or any combination of these may be used. Seal strips are made up of very thin
metal strips sandwiched together and bolted to both side of the bundle. When the bundle is
inserted into its shell the seal strips make contact with the side of the shell, thus providing the
seal.

IMPINGEMENT BAFFLES AND EROSION PROJECTION

An impingement plate, or other means to protect or curtail erosion to the shell side of the
tube bundle from incoming fluids may be required if they exceeds certain entrance line values
as determined by a formula given into the TEM standard. Normally the impingement plate is
made out of plate material similar to the bundle material and is either welded or brazed to the tie

43
rods of the bundle. The impingement plate should never be attached to the tubes. A properly
designed diffuser may be used to reduce line velocities at the shell entrance or inlet nozzle. The
diffuser material should be the same as the shell material.

FLOATING HEAD

The most common type of floating head is the flanged and shallow dished. The floating head
may be bolted directly to the floating head tube sheet of the bundle or may be attached by a
backing ring device. The material of construction for split rings or other internal floating head
backing devices is the same as the material used for shell interior. Pass partition, plates, when
required, is usually plate material which is cut to be contour of head and attached to the head by
a full penetration fusion weld.

BOLTING

Except for special design consideration, flanges are through bolted with stud bolts threaded
full length with a removable not on each end. Stud bolt length should be such that the nuts are
fully engaged and project through approximately 3.2 mm on each end. The minimum
permissible TEMA bolt diameter is 3/4" (19 mm). For sizes 1" (25.4 mm) ans smaller, coarse
thread series is required by TEMA and for larger sizes an 8 - pitch thread series is required.

CORROSION ALLOWANCE

Pressure Parts:

All carbon steel pressure parts, except tubes, have a corrosion allowance of 1/8" (3.2mm)
unless service conditions make a different allowance more suitable and specified by the
purchaser.

Internal Covers:

Internal covers are to have a corrosion allowance on each side.

Tube Sheets:

Tube sheets are to have corrosion allowances on each side with provisions that, on the
grooved side of a grooved tube sheet, the depth of the pass partition groove may be considered

44
as available for corrosion allowance.

External Covers:

Where flat external covers are grooved, the depth of the groove may be considered as
available for corrosion allowance.

End Flanges:

Corrosion allowance applies only to be inside diameter of the flanges.

Non Pressure parts:

Non pressure parts such as tie rods, spacers, baffles and support plates have no corrosion
allowances.

Floating Head Backing Device:

Floating head backing devices and internal bolting have no corrosion allowance.

Pass Partition Plates:

Pass partition plates have no corrosion allowance unless, specified by the purchaser.

Alloy Parts:

No corrosion allowance is added to alloy parts except as specified by the purchaser. When
weld metal overlay cladding or cladding is used, the nominal thickness of the cladding is
usually the available corrosion allowance.

Tubes:

Unless specified by the purchaser the corrosion allowance for tubes may be arbitrarily set at
between one half and one third the original nominal thickness, depending on service and
experience.

SUPPORTS AND FOUNDATIONS

45
 All tubular exchangers are required to be provided with supports which are designed to avoid
under stress or deflection in either the supports or shell. Horizontal units are provided with at
least two supporting saddles with holes for anchor bolts. The holes in at least one of the
supports are required to be elongated to provide for expansion of the shell. The saddles are
mode of plate material rolled to the OD. The plate material should be the same material as the
shell. The saddle is attached to the shell of the exchanger by a full filled weld and is welded all
the way around.

A vent hole or tell tale hole is drilled in the bottom of the saddle, max size 1/4" (6.4 mm),
when the saddle is welded all the way around. In some cases, a gap in the weld may be left near
the bottom of the saddle for venting. For vertical exchangers, supports of sufficient size are
required to carry the unit in a supporting structure of sufficient width to clear shall flanges.
Foundation must be designed so that the exchanger will not settle and cause the piping to
transmit excessive strains to the nozzles of the exchanger. Foundation bolts should be set to
allow for setting inaccuracies.

In concrete footings, pipe sleeves at least one size larger than the belt diameter slipped over
the bolt and cast in plate are best suited for this purpose, as they allow the bolt centre to be
adjusted after the foundation is set. Foundation belts should be loosened at one end of the
exchanger to allow free expansion of the shell. The slotted helps in the supports are provided for
this purpose. The exchanger must be set level and square so that pipe connections may be made
without forcing.

GROUND WIRE

All exchangers are provided with a ground wire in case they are struck by lightning. This
ground wire is attached to one of the foundation bulbs on one end of the exchanged and runs
down into the ground.

LIFTING DEVICES

Channel, bonnets, floating heads and shell covers which weight over to pounds are required
to the provided with lifting legs, rings or tapped holes for eyeballs for lifting.
46
EXCHANGER GASKETS

All gaskets are required to be made in one piece, but does not exclude gasket made integral
by welding. Metal jacketed or solid metal gaskets are required for floating head joints, all joints
for pressures of zoos; and over, and for all joints in contact with hydrocarbons. Other gasket
material may be specified by agreement between the purchaser and the manufacture to meet
special service conditions and flange design. We two gaskets are compressed by same bolting,
gasket material and areas shall be selected so that both gasket seal, but neither is crushed at the
required bolt load

CHAPTER 4

4.0 INTRODUCTION TO CATIAV5R16

CATIA: Computer Aided Three Dimensional Interactive Application. It was developed by
Dassault Systems in 1981 and it is located in French. Versions of CATIA are V1, V2, V3, V4,
V5 and V6 more companies are using from V4 only. Now in the market many companies are
using V5R16 and in V5 we have many versions from V5R1 to V5R21

It is a tool based software these tools we call as features, so it is a feature based software .It is
a parametric software, parametric mean while designing or after completing the design we can
change the parameters of the component.

Definition of Software: Feature based parametric bidirectional associative software.

It is a advanced designing software compared to AutoCAD, and in AutoCAD we can

complete all the tasks in single window, but in this we have different windows those windows
we call as modules, the main modules in designing are

1. Sketcher (To know about 2d tools only)

2. Part modelling (To create any solid models)
3. Assembly (In this just we insert the components already created in part)
4. Drafting (To generate the views with projections, dimensions, BOM, etc.)
5. Wireframe and surface designing (To create the surfaces only without thickness)

47
 6. Generative Sheet metal Design (Total design follows the fixed thickness)

Modeling Of Heat Exchanger Using Advanced Modeling Software CATIAV5R16

Open CATIA Software – Go to Start menu – Mechanical Design – Part Design – It opens
part module, now select front plane - select sketch tool – now selected plane will be rotated
towards parallel to the screen, now draw the required cross section to create the shell cylinder
with required dimensions as shown below.

FIG: 1

Select exit work bench – now we are in part module, select the shaft tool – select the cross
section – select horizontal axis and give the angle 360, the cylinder will be created as shown
below.

48
 FIG : 2

FIG: 3

Create a plane parallel to right plane with 400 mm and on that plane create the sketch as
shown below, then exit work bench use the pad tool to add the material with 10mm thick as
shown in fig : 5 plate with holes and mirror it with right plane to create one more plate other
side.

49
 FIG : 4

To see the internal parts the model is shown with wireframe.

FIG: 5

50
 Create the sketch on plate to create the tubes with required dimensions between two plates,
and use the pad tool to add the material to the sketch as shown below fig: 6.

FIG: 6

To see the internal geometry clearly split the model up to half towards front side it looks as
below.

51
 FIG: 7

Create a plane above top plane with required dimension, create a circle on the new plane and
pad it with up to next.

FIG: 8

FIG: 9

Do the same procedure as above for flange to the inlet opening.

52
 FIG: 10

Draw a sketch on the flange and use pocket tool to remove the material as shown below.

FIG: 11

Create a point at origin and create a line perpendicular to front plane and select the part as
shown below and pattern it as shown below.

53
 FIG: 12

After patterning the part hide the planes whichever we do not required, it looks finally as
below.

FIG: 13

54
 Create a plane as shown below and offset one more with required distance, on the newly
created plane create the extension portion as shown below same as above method.

FIG: 14

Create a point at origin and create a line perpendicular to front plane and select the part as
shown below and pattern it as shown below.

55
 FIG: 15

After patterning the part hide the planes whichever we do not required, it looks finally as
below.

FIG: 16

Split the model with split tool to see the component as below with respect to front plane.

56
57
4.1 Drafting
Open the drafting module and generate the views with cross section and generate the
dimensions automatically as shown below.

58
 CHAPTER 5

Introduction to ANSYS:

The ANSYS Workbench platform is the framework upon which the industry’s broadest and
deepest suite of advanced engineering simulation technology is built. An innovative project
schematic view ties together the entire simulation process, guiding the user through even
complex multi physics analyses with drag-and-drop simplicity. With bi-directional CAD
connectivity, powerful highly-automated meshing, a project-level update mechanism, pervasive
parameter management and integrated optimization tools, the ANSYS Workbench platform
delivers unprecedented productivity, enabling Simulation Driven Product Development.

ANSYS works on three principles; those are Penalty method, Lagrange method and
augmented Lagrange method. These principles used in the process of contact analysis and non –
linear analysis.

In this project ANSYS 13.0 played a major role, all the analysis was done with the
implementation of ansys. Mainly Modal ANSYS and Static Structural analysis were done in this
Project.

Modal and Stress Analysis was done on master rod and thermal analysis was done on piston.

5.1 MODAL ANSYS:

In this Modal ANSYS, only the deformation of the component was calculated with applying
forces and boundary conditions. The deformation will be calculated at different natural
frequencies and it was mentioned as different modes. Applying of the boundary conditions will
give you the specified directional deformation along with the total deformation.

5.2 Static Analysis

After the preprocessing, the solution has to be done. From solution phase, choose the new
analysis as static. Then solve the current load step option. The solution will be done, the
following table given the Von – Misses stress at various loads

59
 GEOMETRY

FIXED SUPPORT

60
 TOTAL DEFORMATION (MODE SHAPE 1)

TOTAL DEFORMATION (MODE SHAPE 2)

61
 TOTAL DEFORMATION (MODE SHAPE 3)

TOTAL DEFORMATION (MODE SHAPE 4)

62
TOTAL DEFORMATION (MODE SHAPE 5)

TOTAL DEFORMATION (MODE SHAPE 6)

63
 FREQUENCIES

5.3 STATIC STRUCTURAL ANALYSIS

FORCE

EQUISTRESS

64
 TOTALDEFORMATION

5.4 THERMAL ANALYSIS

65
Temperature application

Heat flow

Total heat flux

66
Directional heat flux

67
 RESULTS

MODAL ANALYSIS
S.No TOTAL DEFORMATION FREQUENCIES
1 5.808 117.39
2 6.6569 270.51
3 3.8265 277.04
4 3.8697 289.82
5 5.4906 330.98
6 7.4078 482.68

STRUCTURAL ANALYSIS
S.No FORCE EQUISTRESS TD
1 5000 8.3617 0.023

THEREMAL
ANALYSIS
S.No TEMP HEAT FLOW TOTAL DIRECTIONAL HEAT
HEAT FLUX FLUX
1 1000 20 0.00216 0.000722

68
 CHAPTER 6
CHECKING THE DESIGN
6.0.1. Constructional details
 Inside diameter of the tube dr
 Thickness of the tube
 Outside diameter of the tube ‘does'
 In side diameter of the shell
 Number of the tubes
 Number of the pass

2. Details of hot oil

 Dynamic viscosity
 Density
 Thermal conductivity
 Specific heat

3.Details of aromatic hydrocarbons

 Dynamic
 Viscosity
 Density

4. Length of the tube of existing heat exchanger and the new heat exchanger

 Total length =6689mm

 Average length of the tube =6.689mm

 Length new heat exchanger =800mm

 Average length of new heat exchanger =160mm

5. Operating conditions of existing heat exchanger and new heat exchanger

 Mass flow rate of hot oil 'mh'

 One time oil passes 120 tubes Mass flow rate =66173kg/hr
 of aromatic hydro carbons 'mc" Inlet temperature =64708 kg/hr.
 of hot oil 'Thi' =320°c
 Out let temperature of hot oil 'tho* =270°c
 Inlet temperature of aromatic hydro carbons 'Tcj' =217°c
 Outlet temperature of aromatic hydro carbons 'Tco '=230°c

69
 New heat exchanger

 Mass flow rate of hot oil 'mh'

 One time oil passes 5 tubes Mass flow rate =2757.208kg/hr
 of aromatic hydro carbons 'mc" Inlet temperature =2696.166
 of hot oil 'Thi' =320°c
 Out let temperature of hot oil 'tho* =270°c
 Inlet temperature of aromatic hydro carbons 'Tcj' =217°c
 Outlet temperature of aromatic hydro carbons 'Tco '=230°c

Analysis of shell of an heat exchanger

S.NO CONVECTION INPUT TEMP OUT-PUT TEMP TOTAL HEAT FLUX DIRECTIOAL HEAT
FLUX

1 1 22 22 1.5397x10-7 9.5606x10-8

2 2 22 22 1.5281x10-7 9.5065x10-8

3 3 22 22 1.5183x10-7 9.645x10-8

4 4 22 22 1.4825x10-7 9.2908x10-8

5 5 22 22 1.4769x10-7 9.4146x10-8

6 6 22 22 1.5819x10-7 1.0209x10-7

7 7 22 22 1.5266x10-7 9.5986x10-8

8 8 22 22 1.5495x10-7 9.4229x10-8

9 9 22 22 1.5067x10-7 9.29x10-8

10 10 22 22 1.4892x10-7 9.6833x10-8

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Analysis of shell using convection T.H.F and D.H.F

12

10

8
Series 1
Series 2
6 Series 3
Series 4
Series 5
4 Series 6

0
total heat flux directional heat flux convection

71
 Analysis of tube of an heat exchanger

Heat Heat Temperature Total Heat Flux Directional Heat Flux

Convection Meshing
Flow Flux Max Min Max Min Max Min

1 10 10 0.005 131.47 131.47 103.08 98.691 101.87 -102.25

2 15 15 0.006 104.11 104.1 153.2 148.95 153.2 -153.2

3 20 20 0.007 94.983 94.981 208 196.72 204.43 -204.42

4 25 25 0.008 90.422 90.42 257.59 247.21 255.75 -256.13

5 30 30 0.009 87.794 87.58 332.75 281 323.88 -324.34

6 35 35 0.010 85.91 85.79 392.3 333.99 373.63 -373.78

7 40 40 0.011 84.55 84.55 438.34 386.89 418.12 -408.36

8 45 45 0.012 83.605 83.532 481.74 430.93 466.84 -469.91

9 50 50 0.013 82.83 82.77 535.16 484.98 520.46 -524.28

10 55 55 0.014 82.22 82.19 580.7 530.23 569.07 -570.81

Output of heat exchanger using stainless steal

72
 CONCLUSION

The modeling and analysis of the heat exchanger was done by using advanced design
software CATIA V5 and three types of analysis was done by using FEA analysis software
ANSYS 14.0.All the results are acquired and tabulated.

1. Tar column reboiler E4509 was found failing in service and the cost of each failure was
found significance as it can affect the production.

2. The one of exchanger tube was found tried with SS-316 and incoloy -825 tubing as per
design check found incoloy 825 as the only suitable one .as the thermal Conductivity of incoloy
-8251s considerably higher than of SS-316.

3. The vibration of tube is also found tube season of failure which can be prevented by
installation of DTS strip in between tubes

4. Change in hot oil inlet and out let position or the direction of flow of hot oil also can give
results as their will be marginal decrease in wall temperature of tube.

5. Change in design to a kettle type reboiler also can improve the life of the exchanger as the
tube bundle will be immersed fully in liquid during operation their by reducing all temperature.

Therefore it is recommended that the tube bundle shell be made in incoloy 825 tube bundle
made with DTS strip and modify shell to a kettle type exchanger.

73
 REFERENCES

1. Heat and Mass Trans.fer-R.K.Raj put

2.Heat and Mass Transfer-Mahesh .M. Rathore

3.Perry's chemical engineering data book

4.Heat and Mass Transfer-p.K.Nag

5.Heat and Mass Transfer data book-Dom kundwar

6.www.hocl.com

74