Aker Kvaerner CL-PC-002 Rev 00

Check List for Heat

Powergas Exchangers
Page 1 of 9

AKER KVAERNER POWERGAS INDIA LTD

PROCESS DEPARTMENT

Checklist CL-PC-002
Revision 00

Checklist for Heat Exchangers

00 10.12.07 JVT SKS SKS

Rev No Date Prepared by Checked by Approved by
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 2 of 9

HTRI Input Checks

Sr no. Check Status

PROCESS CHECKS
1. When exchanger duty is not specified the exchanger flow rates are respected. There may
be difference in shell and tube side duties.
2. If temperatures are specified temperatures are always respected and weight fraction is
calculated. Similarly weight fraction respected and temperature calculated with
temperature is not mentioned. Ensure that the calculated values are consistent.
3. Design pressures conform to philosophy outlined in design basis.
4. Utility fouling factors to conform to values specified in project design basis
5. Shell/Tube MOC and corrosion allowance specified in datasheet conforms to guidelines
provided in project design basis/Material Selection Diagram
6. Fluid allocation is in line with atleast few of the following guidelines:
• Viscous fluids generally on shellside
• Corrosive fluids on tubeside
• More fouling fluid on tubeside
• High pressure steam on tubeside
• Cooling water on tubeside (unless specifically requested by client licensor)
• If cooling water on shell side provide back washing / air / nitrogen rumbling
provision (to be shown in P&ID)
CONSTRUCTIONAL CHECKS
SHELL
7. TEMA type
Shell Tube
(hr m2 °C/Kcal) (hr m2 °C/Kcal)
Fixed tube sheet* <= 0.0002 >0.0002
Floating head >0.0002 >0.0002
U tube >0.0002 <=0.0002
* Inlet streams do not differ by more than 50 – 60°C to avoid bellow
8. Fixed tube sheet exchangers should be generally avoided in refinery services (For avoiding
expansion bellows which are more prone to failure) except on vertical thermosiphon.
9. ‘F’ shell delta P should not exceed 1 Kg/cm2 and/or temperature change of both the fluids
should be less than 130oC. To avoid leakage in longitudinal baffle
10. Use nearest std pipe size when shell ID is less than 450 mm
11. For removable bundle exchangers (floating head and U-tube)
• Shell ID shall not be greater than 1400 mm. (max. limit to be checked with client)
• Bundle weight should not be greater than 15 T (max. limit to be checked with client)
• Exchanger which are located at higher elevation weight & size is more critical
12. For fixed tube sheet exchangers shell ID and exchanger weight shall depend upon
transportation restriction.
13. Do not stack exchangers for very dirty and corrosive fluids
TUBES
14. Tube OD and thickness specified in datasheet shall be in line with project design basis
15. In any case, tube OD is not to be less than ¾”
16. For tube side fouling factor equal to or greater than 0.0004 hr m2 °C/Kcal, use 1” tubes. Check
fouling factor threshold in design basis.
17. Tube length
• 6 M preferred tube length (longer tube length may be used for large exchangers)
• For longer tube length check layout constraints.
• Generally follow TEMA tube lengths
• Standard tube length criteria is not applicable for U tubes
18. Use triangular pitch only if the shell side fouling factor is less than 0.0002 hr m2 °C/Kcal.
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 3 of 9

Use triangular pitch preferably for fixed tube sheet exchangers.

19. For square pattern, tube pitch shall be either 1.25 times tube OD or tube OD + 6 mm which
ever is larger
20. Minimum pass partition lane width shall be 25 mm
21. Floating head and U tube exchangers should have even number of tube passes. Fixed tube
sheet exchanger shall have one or even number of tube passes. In exceptional circumstances
floating head with one tube pass and internal bellow arrangement shall be used.
22. The table below shows the maximum number of tube passes for given exchanger diameter.
Shell ID Preferred tube passes Max. tube passes
349 2 4
400 4 6
600 6 8
800 8 10
1000 10 12
23. Check the minimum permissible ‘U’ Bend ratio
Inner tubes may be criss cross to reduce pass-lane width and accommodate more tubes.
24. Impingement plate shall be generally rectangular. (check dimensions)
25. Bundle inter-changeability & 180° bundle rotation shall be provided if required by client.
26. Provide sealing strip to reduce ‘C’ stream (one pair per 6 tube rows). Sealing strip should be
in the baffled area and not in the window.
27. Provide sealing rods to reduce ‘F’ stream. If the diameter of sealing rod is different than the
tube OD mention that.
BAFFLES
28. Use parallel baffle cut (vertical cut) for
• Two phase flow on shell side
• Shell side fouling factor is greater than 0.00061 (MKH units)
• Double segmental baffles
• F shell
• 180° rotation of bundle is specified
29. Use perpendicular baffle cut (horizontal cut) for
• Liquids
• Vertical exchanger to maximize the heat transfer at the inlet and outlet spacing
30. Odd number of cross passes shall be used as far as possible for perpendicular cut
31. Even number of cross passes shall be used for double segmental baffles
32. For single segmental baffle cut shall be between 15% to 45%. Preferably 25%
33. Central baffle spacing shall be between 1/5th of shell ID to one shell ID. Preferably 0.4 times
Shell ID
34. For segmental NTIW baffle cut shall be greater than 15%.
35. For floating head and ‘U’ tube exchanger provide full support baffle
For large diameter ‘U’ exchangers provide additional support after ‘U’ bend also.
36. Minimum distance of the support plate from the floating tube sheet shall be 180 mm.
37. The baffle edge shall intersect centre lines of the tube row or go through the centre of a pass
partition lane.
Impingement Plate
38. All shell-side impingement plates shall be of sufficient size (extend at least 30mm beyond the
projected bore of the nozzle in all directions) to prevent direct impingement on the tubes.
Data from P&ID
39. Exchanger type indicated on P&ID matches with the data sheet
40. Nozzle numbers & size (ideally the exchanger nozzle size should be equal to the line size)
41. Shell & tube side flow direction – Top / bottom or bottom / top
42. Auxiliary nozzles and their sizes
43. Nozzle sizes shall not exceed 50% of the exchanger ID
Data from vessels
44. Tube to Baffle clearance (typically this value should 0.4 mm for all baffle spacing)
45. Baffle to Shell
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 4 of 9

46. Pass Partition lane width

47. Radius of U bend to be considered

Annexure 2: HTRI Output Checks

Sr no. Check Status Recommendations

GENERAL CHECKS
48. There would be several alternative design. Document these
design on the exchanger summary sheet for audit.
49. Run time messages are resolved
50. All the licensor/PMC notes in the exchanger process
datasheet have been taken care of.
51. Exchanger process data has been respected by HTRI
52. Check the stream property graph.
Check temperature profile
53. Exchanger (gross / effective) Area
54. Overdesign margins have been maintained for duty,
flowrate and surface area.
55. Coefficient shell, tube, fouling and which side is
controlling. How the HTC can be improved?
56. To improve shell side HTC • Change the Shell to F / G
type
• Decrease tube pitch
• Use smaller diameter
tubes
• Use finned tubes
• Add sealing strips
• Adjusting baffle cut and
pitch
57. To improve tube side HTC • Increase tube length
• Decrease tube diameter
• Switch tube side fluid to
shell
• Decrease number of
tubes
• Use tube insert
58. Check that HTC calculated by HTRI are consistent with
documented HTC for similar service
59. Has the allowable pressure drop been utilized? Would a
change in pressure drop reduce the exchanger area
substantially?
60. The difference between specified and calculated number of
tubes should be positive but not very high. In case of large
difference the tube layout should be checked to avoid
bypass streams.
61. Bundle weight lower than 15 MT (check in design basis)
for removable bundle exchangers.
62. Fluid velocities are above minimum value and below
maximum value for maximum and normal flow rates.
HEAT TRANSFER PERFORMANCE
63. Leakage stream A,C,F are less than 20% and B stream is • Increase baffle spacing and
greater than 40% cut
A stream < 0.2 • To reduce C stream
B stream > 0.4 fraction, use seal strips
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 5 of 9

C stream < 0.2 • To reduce F stream fraction,

E stream < 0.2 change number & size of F
F stream < 0.2 stream seal rods
• To reduce A stream
fraction, reduce the
clearance between tube &
baffle
• To reduce E stream
fraction, switch to double
segmental baffle
64. MTD variation across the tube length. Can it be improved
by changing flow pattern?
65. Temperature profile distortion factor (delta) greater than Use 2 or more shells in series
0.8 when temperature distortion
factor is high.
66. Ratio of window to cross flow velocity shall be between
0.8 to 1.2 for segmental baffles
Ratio of window to cross velocity shall be between 2 to 3
for NTIW baffles.
67. Window flow penalty factor shall be as high as possible
max value 0.92 if not change baffle cut.
68. When outlet temperature of hot fluid is equal to outlet Run exchanger in simulation
temperature of cold fluid, an internal temperature pinch mode to check penalty
may exist due to crossflow. Make plot of MTD across the Increase number of baffles by
exchanger. one or change baffles
orientation.
69. If outlet temperature of hot fluid is lower than outlet Make a plot of enthalpy versus
temperature of cold fluid, temperature cross probably temperature and determine the
exists. Incase of temperature cross run the problem in number of shell required to
simulation mode to check how serious the temperature avoid temperature cross.
cross problem is.
PRESSURE DROP CHECKS
70. Calculated shell side pressure drop shall be less than Try the following alternatives
allowed pressure drop for maximum flow/duty case in the given order
• Manipulate baffle spacing
and cut
• Double segmental baffle
• J type shell – single
segmental
• J type shell – double
segmental
• E shell NTIW
• X type shell
• Increase tube pitch
71. Calculated tubeside pressure drop shall be less than For reducing DP try following:
allowed pressure drop for maximum flow/duty case • Increase tube OD if possible
• Decrease tube length
• Decrease number of tube
passes
72. Is shellside pressure drop not utilized fully and shellside • Decrease baffle spacing and
heat transfer coefficient is controlling? baffle cut to the extent
possible
• Increase tube length if
possible
• Use multiple shells in series
or F shell
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 6 of 9

73. Nozzle DP shall not be greater than 20% of the exchanger Increase nozzle size to reduce
DP. the nozzle DP
74. Is tubeside pressure drop not utilized fully and tubeside • Decrease tube OD
heat transfer coefficient is controlling? • Increase tube length
• Increase tube passes
75. Velocity Constraints
Fluid Min. Max.
Cooling Water 1 m/s normal Based on MOC
Residues, Hv Oil 1 m/s turndown
Slurry oil 1.5 m/s turndown 2.3 m/s turnup
Rich amine
VIBRATION CHECKS
76. There are no vibration warning
77. Check exchanger for possible vibration in fouled
condition by blocking leakage stream
78. Unsupported tube length does not exceed TEMA span If TEMA span exceeded:
• Decrease baffle spacing and/or
cross passes
• Provide support at U bend,
floating head, Nozzle inlet &
outlet
• Use double segmental baffles
with closer baffle spacing
• Use NITW with intermediate
support plates
79. Fluid elastic instability ratio exceeded (greater than 0.8) If vibration by these possible:
or Vortex induced vibration or Turbulent buffeting • ‘E’ shell and SS baffles
vibration possible different combinations
• ‘E’ shell and SS baffles,
increased tube pitch ratio
• ‘E’ shell and DS baffles
• ‘J’ shell and SS baffles
• ‘J’ shell and DS baffles
• NTIW
• ‘X’ shell
• Rod baffles
80. Acoustic vibration should not be occurring If acoustic vibration possible:
• Change exciting frequencies
like Vortex and turbulent
buffeting by methods
mentioned above
• Add deresonating baffle
81. Shell entrance and exit velocity should not exceed If exceeded:
critical velocity • Increase height under
inlet/outlet nozzles
• Reduce tube unsupported span
at inlet
• Provide partial support plate
under nozzle
• Use J type shells
• Use NTIW design
• Try using Rod baffles
• Use annular distributor
• Check if removing
impingement would help
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 7 of 9

82. Bundle entrance and/or exit velocity should not exceed • Increase nozzle size
critical velocity • Reduce tube unsupported span
at inlet
• Check if removing
impingement would help
• Use divided flow shells like J
shell
83. Nozzle rho*V2 should not exceed specified limit If exceeded:
• Provide impingement plate if
exceeded
• Increase nozzle size
84. Impingement plate shall be provided for:
• vapor and two phase service
• rho*v2 > 2230 for liquid
• rho*v2 > 740 for saturated liquid
85. Check for possible problems due to presence of
impingement plate
86. Sliding strip near the inlet / outlet nozzles affect the
shell and bundle inlet rho*V2.
OPERATIONAL CHECKS
87. Check calculated tube side pressure drop for fouled Tube side fouling layer
condition when the leakage stream are blocked and there is thickness (mm)
certain fouling layer thickness δ t = 134 * R ft (Rft,
•
tube side fouling factor in
m2*hr*C/kcal)
OR
Based on HTRI fouling layer
thickness curves
88. Also check shellside pressure drop and heat exchanger Shell side fouling layer
performance by: thickness (mm)
• Block A stream option in HTRI δ s = 268 * R fs (Rfs, shell
• Block F stream option in HTRI
• Block E stream option in HTRI side fouling factor in
m2*hr*C/kcal)
And specifying the fouling layer thickness OR
Based on HTRI fouling layer
thickness curves
89. Check effect of overdesign on exchanger performance
during start-up with zero fouling resistance and in
SIMULATION mode. Inform Project Lead Engineer
about possible temperatures rises, especially for column
feed/bottom exchangers and reactor feed/outlet
exchangers.
90. For exchangers with steam condensing, there is a
possibility that steam may condense under vacuum when
exchanger is clean (especially when the design is fouling
factor controlled). In such situation a pumping steam trap
may need to be considered.
To Vessels
91. HTRI tube layout
92. Final results
93. Design Pressure (10/13, utility, steam out)
Design temperature (Based on Max. op. temp.)
MOC of exchanger
Corrosion Allowance
NACE, IBR, HIC
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 8 of 9

Stacking details
Mean metal temperature
Cyclic duty if applicable
Cathodic protection for exchanger
Alt. design condition steam-out, chemical cleaning etc.

Final Actions

94. Check consistency of Vessels Exchanger drawing with HTRI run

95. Re-run design from vessels in HTRI with following details:
• Shell ID
• Tubesheet thickness
• Tube thickness
• Baffle thickness
• Baffle inlet and outlet spacing
• Passlane widths
• Tube-baffle hole clearance
• Baffle-shell clearance
• Bundle-shell clearance
• Tie rods (number)
• Sealing strip number
• F stream seal rod diameter & number
• Height under inlet nozzle
• Height under outlet nozzle
• Impingement plate dimensions like width, diameter and
thickness
• Impingement plate height above tube
• Proper tube layout to avoid bypass streams
• Support baffle for NTIW exchangers
• Support baffle below inlet and outlet nozzle
96. Have all the change with respect to ITB properly documented and
approved by the client.
97. Has the client been informed in case of large variation in area as
compared to the ITB area
98. Prepare TEMA data sheet. Update the items mentioned below in the
HTRI TEMA output
Logo, Project details
Revision number
MOC for all parts
Mention holds, notes
Mention holds, notes
Change list, compliance report etc.
Exchanger details: Tag number, Service, Fluids
Baffle orientation
Height under nozzle
Seal rod dia. & number, Sealing strips
Prepare Exchanger GA on separate sheet
For Multi-shell exchanger indicate stacking details
Mean Metal Temperature
99. Normal Operating
100. Start-up
101. Shutdown
 Aker Kvaerner CL-PC-002 Rev 00
Check List for Heat
Powergas Exchangers
Page 9 of 9

102. Steam out

103. Upset case
104. Regeneration
105. Cathodic protection required.