SCAMBIATORI

HEAT EXCHANGERS

GENERAL INFORMATION
OPERATING AND MAINTENANCE OF
Dimensioni e caratteristiche non impegnative. Tolleranze secondo norme. - Dimensions and characteristics of the catalogue are subject to change without notice. Clearances according to international standards.

HEAT EXCHANGERS
SUCCESSFUL PERFORMANCE of heat FAILURE TO PERFORM properly may
transfer equipment, Iength of service and be due to one or more of the following:
freedom from operating difficulties are
Iargely dependent upon:

1. Proper thermal design. 1. Exchanger being dirty.

2. Proper physical design. 2. Operating conditions being different
3. Manner of installation, including design than design conditions.
of foundation and piping. 3. Air or gas binding.
4. The method of operation. 4. Incorrect piping connections.
5. The thoroughness and trequency of 5. Excessive clearance between baffles
cleaning. and shell due to corrosion.
6. The materials, workmanship, and tools 6. Improper application.
used in maintenance and making repairs
and replacements.

SHEET 2001.138

FLOVEX S.p.A. - 20064 GORGONZOLA (MI) - Via C. PORTA 5/11 - TEL. 02-9512611 - FAX 02-95126139
 SCAMBIATORI
HEAT EXCHANGERS
INSTALLATION PLANNING 11. Drain connections should not be 7. lf heat exchanger shell is equipped
1. On removable bundle heat exchan- piped to a common closed manifold so with a bellows type expansion joint, remove
gers provide sufficient clearance at the that it may be determined that the shipping supports per instructions.
stationary end to permit the removal of exchanger has been thoroughly drained.
the tube bundle from the shell. On the OPERATION
floating head end, provide space to permit INSTALLATION AT JOBSITE 1. Be sure entire system is clean befo-
removal of the shell cover and floating 12345 re starting operation to prevent plugging
12345
head cover. 12345
12345 CAUTION: Dress properly for the of tubes or shell side passages with
12345
2. On fixed bundle heat exchanger, 12345 job. You may need any number of refuse. The use of strainers or settling
12345
provide sufficient clearance at one end to 12345 special items-safety hat, safety tanks in pipe lines leading to the heat
12345
12345
Dimensioni e caratteristiche non impegnative. Tolleranze secondo norme. - Dimensions and characteristics of the catalogue are subject to change without notice. Clearances according to international standards.

permit removal and replacement of tubes 12345 shoes, goggles, heavy gloves, ear exchanger is recommended.
12345
12345
12345
and at the other end sufficient clearance 12345 protective devices, etc., for your 2. Open vent connections before
12345
to permit tube rolling. 12345 own protection. Find out what starting up.
12345
12345
3. Provide valves and bypasses in the 12345 items are required and wear therm. 123456
123456
piping system so that both the shell side 123456 CAUTION: A heat exchanger is a
123456
and tube side may be bypassed to permit 1. On receipt of the heat exchanger at 123456
123456 pressure vessel designed for
123456
isolation of the heat exchanger for the jobsite, inspect for shipping damage 123456
123456 operation at certain specific Iimits
123456
inspection, cleaning and repairs. to all protective covers. If damage is 123456 of pressure and temperature. The
123456
123456
4. Provide convenient means for evident, inspect for possible contami- 123456
123456 cooling or process system, which
123456
frequent cleaning as suggested under nation and replace protective covers as 123456 includes the heat exchanger,
123456
123456
maintenance. required. If damage is extensive, notify the 123456
123456 must be safeguarded with safety
123456
5. Provide thermometer wells and carrier immediately. 123456
123456 valves and controls so that these
pressure gauge Pipe taps in all piping to 2. Store under cover in a heated area, if 123456
123456 heat exchanger design conditions
123456
and from the heat exchanger located as possible. 123456 are not exceeded. All operating
123456
123456
123456 personnel should be made aware
close to the heat exchanger as possible. 3. If the heat exchanger must be stored 123456
123456
123456
6. Provide necessary air vent valves for for a period exceeding 30 days, 123456 of these specific design
123456
the heat exchanger so that it can be precautions should be taken to prevent 123456pressures and temperatures.
purged to prevent or relieve vapor or gas rusting or contamination. Following
binding on either the tube side or shell extended storage, it is suggested that the 3. Start operating gradually. See Table
side. exchanger be thoroughly inspected prior 1 for suggested startup and shutdown
7. Provide adequate supports for to installation. procedures for most applications. lf in
mounting the heat exchanger so that it 4. When installing, set heat exchanger doubt, consult FLOVEX Technical office
wilI not settle and cause piping strains. level and square so that pipe connections for specific instructions.
Foundation bolts should be set accurately. can be made without forcing. 4. After the system is completely filled
In concrete footings, pipe sleeves at Ieast 5. Before piping up, inspect all openings with the operating fluids and all air has
one pipe size larger than the bolt diameter in the heat exchanger for foreign material. been vented, close all manual vent
slipped over the balt and cast in place are Remove all wooden Plugs, bags of connections.
best for this purpose as they allow the bolt desiccant and shipping covers 5. Bolting on all gasketed or packed
centers to be adjusted after the foundation immediately prior to installing. Do not joints should be retightened after the heat
has set. expose internal passages at the heat exchanger has reached operating
8. Proper Iiquid level controls and relief exchanger to the atmosphere since temperatures to prevent leaks and gasket
valves and Iiquid level and temperature moisture or harmful contaminants may failures.
alarms, etc., should be installed. enter the unit and cause severe damage 123456
123456 CAUTION: Many heat exchanger
9. Gauge glasses or Iiquid level alarms to the system due to freezing and/or 123456
123456
should be installed in all vapar or gas corrosion. 123456 circulate fluids which are irritating
123456
123456
spaces to indicate any failure occurring 6. After piping is complete, if support 123456 or dangerous to the human
123456
123456
in the condensate drain system and cradles or feet are fixed to the heat 123456 system. These fluids could cau-
123456
123456
prevent flooding of the heat exchanger. exchanger, loosen foundation bolts at one 123456
123456 se problems if bolted or threaded
123456
123456 ionts are not maintaned in a leak-
10. A surge drum should be installed end of the exchanger to allow free 123456
123456
upstream from the heat exchanger to movement. Oversize holes in support 123456
123456 tight condition at operating
123456
guard against pulsation of fluids caused cradles or feet are provided for this 123456 pressures, temperatures and no-
123456
by pumps, compressors or other purpose. 123456
123456 flow, ambient conditions. lf fluids
123456
equipment. 123456
123456 are not irritating or dangerous, a
123456
123456 leak wiIl at least cause a slippery
123456
123456
123456 situation on the floor below. Since
123456
123456
123456 one fluid the heat exchanger is at
123456
123456
123456 hingher temperatures, any leaks
123456
123456
123456 might cause burns.

6. Do not operate the heat exchanger

under pressure and temperature
canditions in excess at those specified on
the name plate.
7. To guard against water hammer, con-
densate should be drained from steam
heated exchangers and similar apparatus
both when starting up and shutting down.
8. Drain all fluids when shutting down
to eliminate possible freezing and
corroding.
9. In all installations there should be no
pulsation of fluids since this causes
139

vibration and will result in reduced

SHEET 2001.

operating life.

FLOVEX S.p.A. - 20064 GORGONZOLA (MI) - Via C. PORTA 5/11 - TEL. 02-9512611 - FAX 02-95126139
 SCAMBIATORI
HEAT EXCHANGERS
MAINTENANCE 7. If the heat exchanger has been in 12. Do not attempt to clean tubes by
12345 service for a considerable length at time blowing steam through individuaI tubes.
12345
12345 CAUTION: Do not remove channel This overheats the individual tube and
12345 without being removed, it may be
12345 covers, shell covers, floating results in severe expansion strains and
12345 necessary to use a jack on the floating
12345
12345 head covers or bonnets until all
12345 leaking tube to tubesheet joints.
12345 tubesheet to break the bundle free.
12345 pressure in the heat exchanger
12345 123456
12345 …A good-sized steel bearing plate should 123456
12345
12345 has been relieved and both shell 123456
123456 CAUTION: Do not blow out heat
12345 be used with a filler board between the 123456
12345
12345 side and tube side are completely 123456 exchangers with air when the
12345 123456
12345 drained. tubesheet face and bearing plate to 123456
123456 normal process fluids or the
123456
protect the tube ends. 123456 cleaning fluids being handled are
123456
123456
Dimensioni e caratteristiche non impegnative. Tolleranze secondo norme. - Dimensions and characteristics of the catalogue are subject to change without notice. Clearances according to international standards.

1. Exchangers subject to fouling (scale, 8. Tube bundles may be lifted 123456 inflamamable.
sludge deposits, etc.) should be cleaned horizontally by means of a cradle formed
periodically depending on specific by bending a light-gauge plate or plates 13. To locale ruptured or corroded tubes
conditions. A light sludge or scale coating into a U shape. Attachments are made in or leaking joints between tubes and tube
on either side at the tube greatly reduces the legs at the U for lifting. sheets, the following procedure is
its effectiveness. A marked increase in recommended;
9. Bundles should not be dragged since
pressure drop and/or reduction in perfor- …Remove tube side channel covers or
mance usually indicates cleaning is baffles or support plates may become bonnets.
necessary. Since the difficulty of cleaning easily bent. Any damage to baffles must …Pressurize the shell side of the
increases rapidly as the scale thickens or be avoided so that the heat exchanger exchanger with a cold liquid, preferably
deposits increase, the intervals between will function properly. water.
cleanings should not be excessive. 10. Following are safe loads for rods and …Observe tube joints and tube ends for
2. Neglecting to keep tubes clean may eyebolts: indication of test fluid leakage.
result in random tube plugging. Consequent
overheating or cooling at the plugged tubes,
as compared to surrounding tubes, will cau- RODS EYEBOLTS
se physical damage and leaking tubes due
size tubes size rods safe load per rod size safe load
to differential thermal expansion of the
metals. 5/8” 3/8” 1,000 lbs 3/4” 4,000 lbs
3. To clean or inspect the inside at the
3/4” 1/2” 2,000 lbs 1” 6,000 lbs
tubes, remove only the necessary tube
side channel covers or bonnets 1” or 11/4” 10,000 lbs
depending on type of exchanger larger 5/8” 3,000 lbs 11/2” 15,000 lbs
construction.
12345
12345
12345 CAUTION: Since many of the 11. When removing tube bundles from
12345
12345 removable components of the heat
14. With certain styles of exchangers, it
12345 heat exchangers for inspection or
12345
12345 will be necessary to buy or make a test
12345 exchanger, particularly in the cleaning, care should be exercised to see
12345
12345 larger sizes, are too heavy for men ring to seal off the space between the
12345
12345 that they are not damaged by improper
12345
12345 to handle, care must be used to floating tubesheet and shell inside
12345 handling.
12345 take this weight with proper
12345
12345 …The weight of the tube bundle should diameter to apply the test in paragraph
12345
12345 rigging to avoid injury. Wear hard
12345 not be supported on individual tubes but 13. Cansult your nearest sales
12345 hats and safety shoes as required.
should be carried by the tubesheets, representative for reference drawings
4. If the heat exchanger is equipped with support or baffle plates or on blocks con
showing installation of a test ring in your
zinc wasting pencils or plates, replace toured to the periphery of the tube
bundles. heat exchanger.
these as required.
…Do not handle tube bundles with hooks 15. To tighten a leaking tube joint, use a
5. To clean or inspect the outside of the
tubes, it may be necessary to remove the or other tools which might damage tubes. suitable parallel roller tube expander.
tube bundle. (Fixed tubesheet exchanger Tube bundles should be moved about on …Do not roI tube beyond the back face
bundles are non-removable.) cradles or skids. of the tubesheet. Maximum rolling depth
6. Some suggested methods at cleaning …To withdraw tube bundles, il is
should be tubesheet thickness minus 1/8”.
either the shell side or tube side are listed recommended that rods be passed
below: through two or more of the tubes and the …Do net reroll tubes which are not leaking
…Circulating hot wash oil or light distilla- load taken on the floating tubesheet. since this needlessly thins the tube wall.
te through tube side or shell side will …Rods should be threaded at both ends 16. It is recommended that when a heat
usually effectively remove sludge or and provided with nuts and should pass exchanger is dismantled, new gaskets be
similar soft deposits. through a steel bearing plate at each end
…Soft salt deposits may be washed out used in reassembly.
of the bundle.
by circulating hot fresh water. …A soft wood filler board should be …Camposition gaskets become brittle
…Some commercial cleaning compounds inserted between the bearing plate and and dried out in service and do not provide
such as "Oakite" or "Dowell" may be
tubesheet face to prevent damage to the an effective seal when reused.
effective in removing the more stubborn
tube ends. …Metal or metal jacketed gaskets in initial
depasits. Use in accardance with the
manufacturer's instructions. …Forged steel eyebolts should be
compression match the contact surfaces
screwed into both bearing plates for
12345 pulling and lifting. and tend to work harden and cannot be
12345 CAUTION:When the heat exchan-
12345
12345 …As an alternate to the rods, a steel cable recompressed on reuse.
12345
12345 ger is cleaned, it is important that
12345
12345 can be threaded through one tube and 17. Use of new bolting in conformance
12345 full characteristics of the fouling
12345 returned through another tube.
12345 material and care exercised in with dimensions and ASTM specifications
12345
12345 …A hardwood spreader block must be
12345
12345 handling them according to of the original design is recommended
12345 inserted between the cable and the
12345 instructions. Use eye protection
12345 where frequent dismantling is
12345
SHEET 2001.140

12345
12345
to prevent damage to your eyes. floating tubesheet to prevent damage to
12345 encountered.
12345 Wear a respirator when required. the tube ends.

FLOVEX S.p.A. - 20064 GORGONZOLA (MI) - Via C. PORTA 5/11 - TEL. 02-9512611 - FAX 02-95126139
 SCAMBIATORI
HEAT EXCHANGERS

GENERAL INFORMATION
OPERATING AND MAINTENANCE OF
Dimensioni e caratteristiche non impegnative. Tolleranze secondo norme. - Dimensions and characteristics of the catalogue are subject to change without notice. Clearances according to international standards.

HEAT EXCHANGERS
TABLE 1
RECOMMENDED START-UP AND SHUT-DOWN PROCEDURES
Caution: Every effort should be made to avoid subjecting the unit to thermal shock, overpressure and/or hydraulic hammer, since
these conditions may impose stresses that exceed the mechanical strength ot the unit or the system in which it is installed which
may result in leaks and/or other damage to the unit and/ar system.

Fluid Location & relative Temp.

Heat Exchanger SheII side Tube side Start-Up
Type of Shut-Down Procedure
Type of Rel. Type of Rel. Procedure
Costruction
Fluid Temp. Fluid Temp.
Start both fluids gradually at Shut down both fluids
Liquid Liquid the same time gradually at the same time
Condensing Liquid
Gas Hot or Cold Start hot fluid first, then hot Shut down cold fluid first,
(i.e. Steam) Gas fluid then hot fluid
Fixed Tubesheet
(Non removable) Start cold fluid firs, then hot Shut down coid fiuid
Bundle Gas
fluid gradualiy then hot fluid
Liquid
Start both flows gradually at Shut down both fluids
the same time gradually at the same time
Liquid Cold Hot
Start cold fluid firs, then hot Shut down hot fluid first,
Gas
fluid then cold fluid
Liquid Liquid Shut down hot fluid first,
U-Tube then cold fluid
Packed Floating
Head Condensing Liquid Shut down cold fluid first,
Packed Floating Gas Hot or Cold then shut down hot fluid
Tubesheet (i.e. Steam) Gas gradually
Start cold fluid firs, then start
Internal Floating hot fluid gradually
Heat Gas
(All these types Liquid
Shut down hot fluid first,
have Removable then cold fluid
Bundles) Liquid Cold Hot
Gas

General Comments:
1) In all start-up and shut-down operations, fluid flows should be regulated so as to avoid thermal shocking the unit regardless of
whether the unit is of either a removable or non-removable type construction.
2) For fixed tubesheet (non-removable bundle) type units where the tube side fluid cannot be shut down, it is recommended that
(1) A bypass arrangement be incorporated in the system, and (2) The tube side fluid be bypassed before the shell side fiuid is
shut down.
141

SHEET 2001.

FLOVEX S.p.A. - 20064 GORGONZOLA (MI) - Via C. PORTA 5/11 - TEL. 02-9512611 - FAX 02-95126139