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Heat Exchanger Extraordinaire Expo
Jonathan Martens [email protected]
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Heat Exchangers• Specifications
• Temperature/Pressure Ratings
• Design Selection
• Testing
• Configuration Options• Single Pass
• Double Pass
• Expandable Capacities
• Double Wall
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Heat Exchangers• Diagnostics
• Common Installation Errors
• Pressure
• Temperature
• Cleaning• Decision to Replace or Clean
• Chemicals
• Process
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Temperature and Pressure Rating
• Heating
• 250 Degree F.
• 250 PSI
• Cooling
• 180 Degree F.
• 150 PSI
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What Does that Mean?
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Heating Design
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Heating TemperaturesApproach Temperature:
Minimum of 10 Degree F.
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Cooling TemperaturesApproach Temperature:
Minimum of 2 Degree F.
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Heating Flow RatesHeat Exchanger Flows
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Heating Pressure Drops
Equal volumes on each side of the heat exchanger means
that one side has a much higher fluid velocity. This is true for
plate/frame and brazed plate heat exchangers but not shell
and tube
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Cooling Pressure Drops
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Fouling Factor/Oversurfacing
Fouling factor is an engineering safety factory.
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Heat Exchanger Turndown
• Reynolds Number Below 2000 Is Laminar
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Heat Exchangers Testing• Nameplate Pressure Rating (NPR)
• Hydro Test Pipe to 1.5 X NPR
• ASME Certifies Heat Exchangers as 1.3 X
NPR
• European Standard is 1.2 X NPR
• Heating Hydro Tests to 375 PSI
• Cooling Hydro Tests at 225 PSI
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Single-Pass
Heat
Exchanger
Linan Beta Mechanical & Electrical Co., Ltd
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Two-Pass
Heat
Exchanger
Danfoss ASEAN
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Expandable
Capacities
SWEP International AB
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Expandable
Capacities
http://1.bp.blogspot.com/_l-cNNS3j7UU/S7FhqbBQwII/AAAAAAAAAR4/AsODQ-al8k8/s1600/pack.png
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Double Wall (Domestic Hot
Water)
http://tse2.mm.bing.net/th?id=OIP.M9b673b3070f9375fc0f985629f5c35b1o0&pid=15.1
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How often to clean if no signs of trouble?
Your Preventative Maintenance Friend
• Building Hx • House side - 1x/5yrs
• District side – 1x/5yrs
• DHW Hx• House side – 1x/yr
• District side – 1x/5yrs
• Process Cooling Hx• Process side – 1x/yr
• District side – 1x/yr
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Pressure
Diagnostics
High Pressure
Drop on either
side of the
heat
exchanger.
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Pressure Mechanical Rating
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Low Temperature Differential
250
190 150
180
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Low Temperature Differential
250
190 150
165
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Temperature Mechanical Schedule
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How often to clean if no signs of trouble?
Your Preventative Maintenance Friend
• Building Hx • House side - 1x/5yrs
• District side – 1x/5yrs
• DHW Hx• House side – 1x/yr
• District side – 1x/5yrs
• Process Cooling Hx• Process side – 1x/yr
• District side – 1x/yr
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Installation SNAFUs:
• Horizontal Installation
• Piped from Bottom of
Header
• Thermal shock
• Oversized (+2x
needed capacity)
• Parallel flow
• No P/T gauges
• No CIP ports
http://www.corrview.com/images/phocagallery/109-Improper_Dielectric_Fittings/thumbs/phoca_thumb_l_109_001.jpg
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Time to Replace
Signs of
physical
damage or
leaks
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Time to Clean Vs. Replacement
• Doesn’t meet the criteria of one of the
common installation errors
• No signs of Physical Damage or Leaking
• Heat Exchanger Replacement is > 3 X Cost
to Clean
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Cleaning: The Process
• Test loop water sample to identify
the foulant
• Mix chemicals to appropriate
concentrations – excessive pH in
either direction can adversely
accelerate corrosion rates
• Connect pump in reverse of
typical flow
• Note:• Do not exceed 100F
• Target flow rate: 2 – 9 ft/sec
• Flush hx with city water until
conductivity of rinse water
matches city water
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Cleaning: Determining the Foulant
• Iron Oxides
• Hardness (Calcium,
Magnesium, etc.)
• Biologicals
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Chemical Flush
Time Lapse -
5 Minutes
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Chemical Flush
Time Lapse -
15 Minutes
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Chemical Flush
Time Lapse -
30 Minutes
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Chemical Flush
Time Lapse -
40 Minutes
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Questions?
Thank you!