FABRICATION OF SHELL AND

TUBE HEAT EXCHANGER TO

COOL HYDRAULIC OIL
 M.S. MOHAMED SHUJAHATHULLA
 V.NARENDHRAKUMAR
 R.PRAVEENKUMAR

 Internal guide: Antony Aroul Raj

 A heat exchanger is defined as equipment which transfers the
heat from a hot fluid to a cold fluid.
 A heat exchanger is a device built for efficient heat transfer
from one medium to another, whether the media are separated
by a solid wall so that they never mix, or the media are in
direct contact.
 They are widely used in space heating, refrigeration, air
conditioning, power plants, chemical plants, petrochemical
plants, petroleum refineries, and natural gas processing. One
common example of a heat exchanger is the radiator in a car,
in which a hot engine-cooling fluid, like antifreeze, transfers
heat to air flowing through the radiator.
TYPES OF HEAT EXCHANGERS
 Nature of heat exchange process
 Relative direction of fluid motion
 Design and constructional features
 Physical state of fluids
 Nature of heat exchange process
 Direct contact heat exchangers or Open heat
exchangers
 Indirect contact heat exchangers.
 Regenerators
 Recuperators or Surface heat exchangers
 Relative direction of fluid motion
 Parallel flow heat exchanger
 Counter flow heat exchanger
 Cross flow heat exchanger
 Design and constructional features

 Concentric tubes
 Shell and tube
 Multiple shell and tube passes
 Compact heat exchanger
 Physical state of fluids
 Condensers
 Evaporators

The main considerations taken into account in

the design of heat exchanger for a particular
application are thermal analysis, mechanical
design, minimum pressure drop, design for
manufacture and cost.
 COMPONENTS
 Tube
 Baffle
 Tube Sheet
 Shell
 End Covers
 O-Ring
 Compressed Asbestos Fibre (CAF) Gasket
SHELL AND TUBE HEAT EXCHANGER TO
COOL HYDRAULIC OIL
 The aim of the project is to design and fabricate a heat
exchanger of 5 lpm capacity to cool the hydraulic oil coming
from power pack.
 Hydraulic oil is used in power pack to actuate hydraulic
cylinders to carryout various functions. Once the oil is pumped
from hydraulic pump to the cylinder, after the actuation, the
oil gets heated up and returns to the oil sump.
 Due to the accumulation of heat in the hydraulic oil, the
temperature of oil goes up and thus there is a decrease in the
viscosity of hydraulic oil. Thus it is necessary to cool the oil
to bring down the temperature
 Specification:

 Oil side inlet temperature = 48c

 Oil side outlet temperature = 40c
 Water side inlet temperature = 32c
 Water side outlet temperature = 38c
 Oil flow rate = 5 lpm or
3m3/hr
 Velocity of oil flow = 8.65*10-3m/s
 Velocity of water flow = 0.6 m/s
 Specific heat of cold water = 4184 J/Kg K
 MATERIAL SELECTION
 Tube material - Copper - high thermal conductivity .
Therefore the heat is conducted more effectively.
 Fixed (Big): padded with SS304 of 3mm for cost
economy - SS padding to increase rust and corrosion
resistance.
 Floating tube sheet (Small): made of SS304 material.
 Baffle material: made of mild steel – no possibility of
corrison since oil is in contact with the baffles.
Shell material: I) made of mild steel of IS1239 grade.
ii)The inlet and outlet socket IS2062
grade.
iii)The flanges welded on the two sides
of shell made of IS 2062 grade mild steel.
End Cover Material: made of cast iron.
Sealing Material: i)CAF gasket on fixed tube sheet side
ii)nitrile rubber ‘O’ring on the floating
tube sheet
FABRICATION
 TUBE SHEET FABRICATION :
 Machining of MS plate with SS304 padding is done in centre
lathe
 fixed tube sheet is manufactured in the lathe machine of 110mm
outer diameter & 11mm thickness for fixed head.
 Floating head 89mm outer diameter & 15mm thick is also made.
 On the tube sheet face a undercut of 3mm is made to house a
4mm thick SS304 padding.
 The tube sheet with padding is kept on the hydraulic press, then
tag welded with a combination welding rod of grade.
 A centre hole of 3mm diameter is made on the padding plate.
 Pad is welded with tube sheet .
 The welded tube sheet with padding plate is machined to the
required size in the lathe machine.
 Three baffles are cut and kept aside.
 On the drilling machine the centre hole of 6.35 mm diameter is
made on this tube sheet.
 Then all the tube sheet and baffles are bolted in bottom together.
 one drill of 6.35mm diameter is drilled and locked to avoid of
turning of plates
 All the holes are drilled initially with the pilot drill of size
6.35mm diameter and finally drilled to the required size of
9.54mm diameter.
 The baffle plate is cut 20% to have smooth turbulence flow inside
the shell tube holes are reamed with reamer of 9.5mm diameter
on drill machine 20 %
MANUFACTURING OF SHELL
 The pipe is cut and trimmed on the lathe machine to
required size.
 Flange is machined on lathe and the PCD is marked on
flanges.
 The holes on the flange are drilled on drilling machine
and finished flanges are welded on the face of the shell.
 Oil inlet and outlet port is drilled on shell.
 Sockets with bsp threads are purchased and welded
(3/4th inch thread) onto shell circumference.
SHELL
SHELL
 END COVERS:
 End covers are machined from cast iron block
to required on lathe.
 The inlet and outlet, water connections on end
covers as per the drawing.
 The PCD is also marked on end covers and
drived to required size as per drawing.
End covers
END COVERS
COPPER PIPES:
Copper pipe of required size are procured from market in
the standard size available and cut to the required dimension.
COPPER TUBES – SIDE VIEW
COPPER TUBES – TOP VIEW
 ASSEMBLY
 The cleaned tube bundle shell is kept on the
assembly table and the tube bundle is inserted
inside the shell in between CAF gasket and in
between the inlet cover and fixed tube sheet.
 Another gasket is provided and cover is fitted
with shell with the help of bolts and nuts.
 The required size of O ring is provided on the
floating tube sheet and outlet cover is also fitted
 TESTING OF TUBE BUNDLE:

 Water is filled on the shell side and the hydraulic pressure

pump is connected with one socket welded on the shell and the
other socket a valve is provided.
 Hydraulic pressure is created to a pressure of 1.5 times more
than the working pressure of the heat exchanger i.e.15kg/cm 2 g
for a operating pressure of 10kg/cm2 g.
 The pressurized heat exchanger is kept for 1 hour and checked
for leaks.
 If there is any leak noticed the hydraulic pump is depressurized
and further expansion carried out until leak stops.
 end covers are also tested parallel for any leakage on the casting
surface to a pressure of 7.5kg /cm2
 CONCLUSION

 The heat exchanger of capacity 5 litres per

minute is designed and fabricated
 The heat exchanger is tested and found to be
capable of maintaining the required inlet and
outlet temperature of water and oil .
 The material selection of mild steel which is
combined with stainless steel at the fixed plate
is effective in cost reduction of the heat
exchanger in an economical manner.
Temperatures maintained
 Oilside inlet : 48˚c
 Oil side outlet : 40˚c
 Water side outlet: 32˚c

 Water side outlet : 38˚c

Thank you