Application of Shell and Tube Heat Transfer:

These are typical Custom-built, Fabricated Equipment predominantly used in Refinery, Petro-Chemical, Fertilizer, and Power Generation Industries for Heat Transfer applications involving Heating, Cooling, Boiling & Evaporation, Condensation, etc.,  The fluids are of different types and properties as per the process & utility.

Design and Constructional Features

These are versatile equipment in various sizes, construction types, materials suitable for wide range of Heat Duties, Heat Transfer Areas, Temperature & Pressure. It has wide application from Cryogenic to High Temperature to more than 500°C with Pressures of Vacuum to more than 480 Bar.

Thermal Design and Rating of the Exchangers is in accordance with licensed HTRI-USA methods. Mechanical Designs are in accordance with International and National Codes and Standards such as ASME Section VIII Div 1&2, TEMA, API 660, IBR as well as to the specific project specifications.

Materials of construction include Carbon Steels, Low Alloy Steels, High Alloy Stainless Steels, Copper Alloys, Nickel Alloys, Brass, Titanium, etc. as per the fluid conditions handled in the Exchangers

The conventional and most predominantly used Shell and Tube Heat Exchanger is basically categorized as i) Fixed Tube Sheet Heat Exchangers, ii) U-Tube Heat Exchangers, iii) Floating Head Heat Exchangers, iv) Tubular Heat Exchangers, v) Tube Bundle Heat Exchangers, vi) Stainless steel heat exchangers, vii) Titanium heat exchangers.

TEMA Standard gives various types of constructions which are all well within the Design and Manufacturing scope of PECPL for the complete range of Pressure and Temperatures as well as the Fluid environment.

These Heat Exchangers have the following constructional features:

a) A cylindrical Shell acting as an envelope housing a Bundle of Tubes. It holds and routes the Shell side Fluid from inlet to outlet at a given Temperature, Pressure, and Flow rate over the Bundle of Tubes.

b) A Tube bundle consisting of Number of Tubes through which Tube side Fluid flows from the inlet to outlet at given Temperature, Pressure, and Flow rate. It has Transverse, Segmental Plate Baffles through which the Tubes are passed holding them as supports as well as routing the Shell side fluid across and along with the Bundle from inlet to outlet of Shell. The baffles also prevent Flow-induced Vibration of Tubes caused by the alternate motion of Shell side Fluid across the Tube Bundle. The Tubes are generally Plain, either Straight or U-Type, however, they can be of Low Fin Type, Coated Type, Fluted Type based on process conditions.

c) Front and Rear End Closures and Bonnets, usually called Inlet and or Outlet Channels to receive tube side Fluid and pass it through the tubes from one end to the other.

d) Required Heat Transfer being achieved between the Shell Side and Tube side fluids across the Tube Wall without intermixing.

Variations in the Type of Tubes and Type of Baffles are made to suit different Heat Transfer conditions. These variations lead to special-purpose units.

PECPL Capabilities

These custom-built Shell and Tube Heat Exchangers are regularly Designed and Manufactured at PECPL in all ranges as the Main Product for various plants such as Oil & Gas, Chemical & Fertilizers, Power, LNG, etc. catering for National, International Clients, and Projects.

The Design & Engineering Department of PECPL is well equipped of qualified Engineers and Technical Staff with Thermal & Mechanical Design Capabilities of these Heat Exchangers.

PECPL possesses all necessary Design and Engineering Software as well as in-house calculation methods for the Design & Detailed Engineering of these Exchangers.

PECPL is a member of HTRI-USA and possesses HTRI programs for Thermal Design and Rating of these exchangers.

PECPL is an approved Fabrication facility with authorization for ASME Stamping of the Exchangers as well as authorized to manufacture according to Statutory Regulations to Indian Boiler Regulations (IBR) and other international regulations as well.

PECPL Has Full-Fledged Fabrication and Testing facilities to manufacture all constructional types of Shell and Tube Heat Exchangers in a wide range of sizes and materials of Construction under reputed Quality Surveillance such as LLODS, BV, TUV, etc.

When required an external partnership of repute is taken for special construction, especially for High Pressure with Special Closures as well as for Special Process applications such as LNG, etc. 

Application of Rod baffle Exchanger:

In certain applicationsof the Process plants with Shell & Tube Heat Exchangers, especially in Gaseous and Condensing services it is critical to minimize shell-side pressure losses, at the same time protecting the Tubes from Flow Induced Vibrations. The best solution for such application will be a Rod Baffle Shell & Tube Heat Exchangers.These Exchangerscan reduce Pressure loss to a significant extent when compared to a traditional Plate BaffledShell & Tube Heat Exchanger due to elimination of Shell side fluid cross flow. Range of application is same as Shell & Tube Heat Exchangers.

Design and Constructional Features:

These Exchangers are basically the custom-built Shell & Tube Heat Exchangers with modification in Baffle construction in the Tube Bundle. All other construction features are similar to Shell & Tube Heat Exchangers.

It consists of a series of closely spaced Shell side Baffles made up of Rods passing parallel in-between Tubes in alternate Tube rows and connected by welding to a circumferential Rim forming a ROD baffle. The Rods are inserted in between the Tube rows tightly giving consecutive 4-sided support to each Tube against Tube Vibration.

Various TEMA Types Viz., Fixed Tube Sheet type, U-Tube Type and Floating Head Type be provided with Rod Baffles with various Shell Configurations.

Thermal performance is favorable due to longitudinal flow of Shell side and Tube side fluids.

These are used for wide range of Duties, Temperatures and pressures generally as in the case of Shell & Tube Heat Exchangers.

Thermal Design and Rating of the Exchangers is in accordance with Licensed HTRI-USA methods. Mechanical Designs are in accordance with International and National Codes and Standards such as ASME Section VIII Div 1&2, TEMA, API 660 as well as to the specific project specifications.

Tubes are of plain type.

Materials of construction include Carbon Steels, Low Alloy Steels, High Alloy Stainless Steels, etc. as per the fluid conditions handled in the Exchangers

PECPL Capabilities.

All the Design & Engineering and Work Shop facilities at PECPL as in the case of Shell & Tube heat Exchangers are well suitable for this product also. These Exchangers are often taken up as Special Product in addition to conventional Shell & Tube Heat exchangers.

Application of Hairpin Heat exchangers:

These Exchangers are a modification of a typical Shell & Tube Heat Exchangers such that a long single Shell pass Multi Tube Shell & Tube Heat Exchanger is half folded into U-shape resembling a Hair Pin profile.

There Exchangers are used,

* For lower and Medium Heat Duties.

* To accommodate higher Temperature cross using single pass cross flow pattern.

* To accommodate low allowableshell side pressure-drop.

* To accommodate large Temperature difference.

* For Higher pressures.

Design and Constructional Features

While the Shell and Bundle resemble the configuration of a Shell & Tube Heat Exchanger, the Closures are of typical construction enabling the removal of U-Tube Bundle out side of Shell for Cleaning and maintenance.

Thermal Design and Rating of the Exchangers isin accordance with Licensed HTRI-USA methods. Mechanical Designs are in accordance with International and National Codes and Standards such as ASME Section VIII Div 1&2, TEMA, API 663 as well as to the specific project specifications.

Tubes are generally plain. However, longitudinal Fins are used in special circumstances.

Materials of construction include Carbon Steels, Low Alloy Steels, High Alloy Stainless Steels, etc. as per the fluid conditions handled in the Exchangers

More often, these are typical Custom-built rather than Standard units of Fabricated Equipment used in Process plants for Heat Transfer applications involving Heating, Cooling and related operations.

PECPL Capabilities

All the Design & Engineering and Work Shop facilities at PECPL as in the case of Shell & Tube heat Exchangers are well suitable for this product also. These Exchangers are often taken up as Special Product in addition to conventional Shell & Tube Heat exchangers. 

Application of Double Pipe Exchangers:

Double pipe Heat Exchangers, often called as Jacket Pipe Heat Exchangers are the simplest type of Exchangers used in the Process Plants for lower Heat Duties and a wide range of pressures and Temperatures.

One fluid flows inside the inner Tube and the other Fluid flows in the annulus between the Inner and the outer Tube in longitudinal direction giving maximum Heat transfer. Counter Flow configuration is more often used.

Design and Constructional Features

Thermal Design and Rating of the Exchangers is in accordance with Licensed HTRI-USA methods. Mechanical Designs are in accordance with International and National Codes and Standards such as ASME Section VIII Div 1&2 as well as to the specific project specifications.

These Exchangers are constructed with Two straight Pipes, one serving as Inner Pipe and another as Outer Pipe welded on to the Inner Pipe with a small annulus space in between. More of such straight units can be joined with U-Bends to form compact serpentine coils in more rows and columns to cater for the required Heat duty.

Materials of construction include Carbon Steels, Low Alloy Steels, High Alloy Stainless Steels, etc. as per the fluid conditions handled in the Exchangers.

Though they are available as Standard units, they are Manufactured as Custom-built units asan add on manufacturing equipment at PECPL, Designed as per given Process conditions.

PECPL Capabilities

All the Design & Engineering and Work Shop facilities at PECPL as in the case of Shell & Tube heat Exchangers are well suitable for this product also. These Exchangers are often taken up as special product in addition to conventional Shell & Tube Heat exchangers.

Application of Helical baffle Exchangers:

These Heat Exchangers are used for higher Thermal efficiency with less fouling in the Process plants for a wide range of Heat duties and Temperatures & Pressures.

Design and Constructional Features:

The Exchangers are a modification of Shell & Tube Heat Exchangers with change in Baffle configuration from Plate Type vertical segmental to inclined type Segmental Quadrants and arranged in a Helix form to the Tube axis along the bundle. They cause nearly a Plug Flow of Shell side Fluid in a Helically Rotational pattern instead of cross flow thus improving the Heat Transfer efficiency.

Tube holes in the baffles are specially drilled inclinedly to an angle to the vertical axis which form a Helix angle when the Baffles are assembled along the Tube Bundle.

Tubes are supported by the baffles effectively against Flow induced Vibrations.

Thermal Design and Rating of the Exchangers is checked when required, in accordance with Licensed HTRI-USA methods. Mechanical Designs are in accordance with International and National Codes and Standards such as ASME Section VIII Div 1&2, TEMA, API 660, IBR as well as to the specific project specifications.

Materials of construction include Carbon Steels, Low Alloy Steels, High Alloy Stainless Steels, etc. as per the fluid conditions handled in the Exchangers.

The Exchangers are custom built to specified Process conditions.

PECPL Capabilities

All the Design & Engineering and Work Shop facilities at PECPL as in the case of Shell & Tube heat Exchangers are well suitable for this product also. These Exchangers are taken up as Special Product in addition to conventional Shell & Tube Heat exchangers.

These are generally of patented designs as Helixchangers and a Partnership is taken for the Design and Manufacture.